ELECTRICALLY POWERED PUMPING UNIT WITH REMOVABLE PUMP MODULES

A modularized, electric pumping unit comprising: a base structure; an electric motor mounted on the base structure; and one or more pump modules. Each of the one or more pump modules comprises a pump and a pump module structure. The one or more pump modules are configured to be removably mounted on the base structure and driven by the electric motor.

FIELD

This disclosure relate generally to the field of pumping. More particularly, this disclosure relates to the field of pumping units comprising an electric motor. Still more particularly, this disclosure relates to modularized, electric pumping units comprising one or more pump modules.

BACKGROUND

Conventional pumping units, such as those utilized for wellbore operations (e.g., for hydraulic fracking) are not modularized. Accordingly, complete pumping units are generally maintained as back-ups, replacing a pump can be a time-consuming operation, and transportation of such a pumping unit can be a challenge, for example, due to weight restrictions.

DESCRIPTION

The description that follows includes example systems, methods, techniques, and program flows that embody aspects of the disclosure. However, it is understood that this disclosure may be practiced without these specific details. For brevity, well-known steps, protocols, structures, and techniques have not been shown in detail in order not to obfuscate the description.

As noted hereinabove, conventional (e.g., electric) pumping units are not modularized. Accordingly, complete pumping units are generally maintained as back-ups, and replacing a pump can be a time-consuming endeavor. Furthermore, the weight of such conventional pumping units can make transportation to some locations of use difficult. The self-contained pump modules, as disclosed herein, can enable back-up equipment to comprise primarily pump modules themselves, and not the entire pumping unit, thus enabling faster pump replacement. Furthermore, as noted above, conventional pumping unit designs are typically too heavy to transport into certain areas. The modular pumping unit design of this disclosure can enable weight removal (e.g., via removal of one or more pump modules from a pumping unit) for transport, as detailed further hereinbelow.

Herein disclosed is an electrically powered pumping unit with removable pump modules. The pumping unit comprises a base structure onto which can be mounted: an electric motor, an electric motor drive assembly, a control assembly, auxiliary electric power supply, at least one pump module, connection points for fluid hoses and electrical cables from the pump module(s), or a combination thereof. Via this disclosure, auxiliary systems can be included as part of the pump module(s) rather than being attached to the base structure.

The base structure is not particularly limited, and can be, for example, a truck, a trailer, or a skid. A receptacle for receiving electrical power can be mounted on the base structure (for example, as a component/connector of a connectors panel as described hereinbelow). Connectors from which to serve fluids, electrical power, controls to the pump module(s), and/or to receive sensor feedback from the pump module(s) can also be mounted on the base structure (e.g., on the connectors panel). The electric motor, the electric motor drive, and/or auxiliary electric power supply can be mounted as part of a base structure assembly. A pump packing lubrication system can also be mounted on the base structure. The base structure can further comprise mounting point(s) or elements to receive complementary mating points/elements from each of the pump modules to properly position and align the pump module relative to the electric motor.

As detailed further hereinbelow with reference to the figures, the pump module comprises: a pump module structure, a pump, a driveline, and pump auxiliary systems. The pump module(s) are removable from the base structure. Removing one or more pump modules from the pumping unit can reduce a weight of the pumping unit for transportation, and to enable more efficient maintenance. The pump module(s) comprise cables and/or hoses that extend to the connectors mounted on the base structure.

In addition to the mounting points to attach the pump module to the base structure, the pump module structure can also comprise lifting components/points for use in lifting/removing the pump module from the base structure. Lifting provisions can be, for example, forklift pockets, lifting eyes, or other lifting means. The pump module structure can be configured to attach to the mounting points to the base structure in such a manner as to assure proper positioning and alignment of the driveline with respect to a motor shaft of the electric motor on the base structure. As described further hereinbelow, the pump module structure may also include guards, guarding, armor, or other physical barriers isolating and preventing access or contact with rotating or otherwise moving components (e.g., driveline) during operation of the pumping module (e.g., isolation or barrier structure designed to prohibit personnel from entering an area having moving parts, e.g., a “red zone,” during operation of the pumping equipment for safety purposes). As described further hereinbelow, the pump module structure may also include deflectors, trays, tanks, drip pans, catch basins, absorbent trays, absorbent pads, and the like, such as for directing or containing fluids.

The pump auxiliary systems can include an oil lubrication pump powered by an electric motor, an oil reservoir, an oil filter, an oil cooler (e.g., comprising a heat exchanger having an electric motor-driven fan), an oil heater (e.g., comprising a heat exchanger or heating element such as an electrical resistance heating element disposed within the oil reservoir or a heating jacket disposed around all or a portion of the oil reservoir), a sensor package (e.g., including sensors for pressure, temperature, position, performance monitoring, etc.), and/or a driveshaft assembly. The pump auxiliary systems can also include suction and discharge manifolds with connections for piping, a pressure relief valve (e.g., fluidically couple to a high pressure outlet of the pump to provide pressure relief in the event of an overpressure condition in the outlet high pressure manifold or piping downstream from the pump (e.g., a blockage or restriction), a pump packing lubrication system, driveshaft clutch and/or driveshaft decoupler, electrical cables, and/or controls systems as part of the pump module.

In embodiments, the electric motor comprises a shaft protruding from two sides/ends thereof to drive two pumps, and the base structure is configured to accommodate two pump modules driven by the single electric motor.

As noted herein, the pumping unit of this disclosure can facilitate transporting of the modular, electric pumping unit. Transporting can comprise removing at least one pump module from the pumping unit prior to transport. The base structure and the pump module(s) can be transported separately, if desired. Once delivered to location, the pumping unit can be assembled by reinstalling the pump module(s).

Pump module removal can include disconnecting the driveline from the electric motor, unplugging electrical cables and/or hoses from the connections (e.g., connector panel) on the base structure, releasing pump module mounting points, lifting the pump module via lifting components/points of the pump module structure, and removing the pump module from the base structure. The aforementioned steps can be taken in reverse for installation of each pump module.

Although not so limited, in embodiments, the pump of each pump module can be a triplex or quintuplex plunger pump. As detailed further hereinbelow, the pump of each pump module can be mounted to the pump module structure of the pump module in a manner that accommodates flexure of the pump module structure. For example, in embodiments, a three-point mounting scheme can be utilized to mount the pump of each pump module thereto, in order to accommodate flexure of the pump module structure

The pumping unit can include any number of pumps. For example, as noted above, in embodiments, the pumping unit can include two pumps. Alternatively, in embodiments, a pumping unit can include a single pump module. In embodiments, one or more of the pump modules have included packing grease systems (e.g., with no fluid connections to base structure). In embodiments, one or more of the pump modules are connected with a remote packing grease system (e.g., a centralized packing grease service). In embodiments, the pump module(s) can include pump life tracking system(s) for component identification, data processing, data storage and/or communications (e.g., internal and/or external).

Having broadly described the pumping unit of this disclosure, a more detailed description will now be provided with reference toFIG.1A, which is a schematic of a modularized, electric pumping unit100, according to embodiments of this disclosure, comprising two pump modules150, including first pump module150A and second pump module150B;FIG.1B, which is a schematic of the modularized, electric pumping unit100ofFIG.1Awith one pump module150A removed;FIG.1C, which is a schematic of the modularized, electric pumping unit ofFIG.1Awith the other pump module150B removed;FIG.1D, which is a schematic of a base structure assembly105; andFIGS.2A-3B, which are schematic views of a pump module150, according to embodiments of this disclosure.

As depicted inFIGS.1A-1C, a modularized, electric pumping unit100(referred to herein simply as a “pumping unit100”) of this disclosure can comprise a base structure101; an electric motor110mounted on the base structure101; and one or more pump modules150. As depicted via brackets, in the embodiment ofFIG.1A, the one or more pump modules150include two pump modules150, comprising first pump module150A and second pump module150B. Each of the one or more pump modules150comprises a pump120and a pump module structure130. The one or more pump modules150are configured to be removably mounted on the base structure101and driven by the electric motor110.

The pumping unit100can further comprise at least one connector panel102comprising connectors103for electrical cables and/or hoses104from the one or more pump modules150, wherein the electrical cables and/or hoses104are configured for supplying fluids, electric power, and/or control signals to the one or more pump modules150, and/or to receive sensor feedback from the one or more pump modules150. One or more of the connectors/receptacles103can be configured for providing/receiving electrical power to the connector panel102.

The base structure101can comprise a truck, a trailer, or a skid. As best seen inFIG.1D, which is a schematic of a base structure assembly105, the pumping unit100can include a base structure assembly105comprising the base structure101, the electric motor110, an electric motor drive160(which can include) an auxiliary electric power supply107, or a combination thereof mounted on the base structure101. A pump packing lubrication system108can be mounted on the base structure101.

The base structure can further comprise one or more mounting points/elements115, and each of the one or more pump modules150can comprise one or more complementary mounting points/elements116, configured such that each of the one or more mounting points115of the base structure101are configured to receive/align with one or more of the one or more complementary mounting elements116of the one or more pump modules150, to position and/or align the pump module150(e.g., a driveline135thereof) with the electric motor110(e.g., with a motor shaft111thereof).

As more clearly depicted inFIGS.2A-3B, each of the one or more pump modules150can comprise the pump module structure130, the pump120, a driveline135, and pump auxiliary systems140. The pump auxiliary systems140can comprise an oil lubrication pump141, an oil reservoir143, one or more oil filters144, an oil cooler145, an oil heater187, a sensor package146(e.g., comprising one or more sensors147for monitoring pressure, temperature, position), a driveline135(“driveshaft assembly”), or a combination thereof. The an oil lubrication pump141can be powered by an auxiliary electric motor142, in embodiments. Oil cooler145can comprise a heat exchanger145′ (e.g., radiator having oil circulating therein) and a fan145″, in embodiments. The oil heater187can comprise a heat exchanger or heating element such as an electrical resistance heating element188disposed within the oil reservoir143or a heating jacket disposed around all or a portion of the oil reservoir143. The oil cooler and/or heater can be controlled by control systems153responsive to temperature of the oil and/or ambient temperature sensed by one or more sensors of the sensor package146. The pump auxiliary systems140can further comprise a suction manifold148and a discharge manifold149(FIG.2C) with connectors for piping, a pump packing lubrication system151(FIG.2C), a driveshaft clutch and/or driveshaft decoupler152, electrical cables and/or hoses104, control systems153, or a combination thereof.

Each of the pump modules150can comprise cables and/or hoses104that extend to one or more connector panels102mounted on the base structure101. For example, two connector panels102are depicted in the embodiments ofFIGS.1A-1C. However, in embodiments, a single connector panel102can be utilized for one, two, or more pump modules150, or a plurality of connector panels102can be associated with each pump module150. As best depicted inFIG.4A, which is a close-up view of a portion of a pumping unit100comprising connectors panel102, according to embodiments of this disclosure connector panel102is mounted on base structure101(rather than on pump module structure130). One or more cables (e.g., electrical cables) and/or hoses104can connect the connector panel102with (e.g., components of) pump module150. A receptacle/connector103of the connector panel102can receive electrical supply for the pumping unit100.

Each of the one or more pump modules150can further comprise one or more lift components113configured for removal of each of the one or more pump modules150from the base structure101. The lifting components113are not particularly limited, and can comprise, for example, one or more forklift pockets, lifting eyes, or a combination thereof.

As depicted inFIG.2BandFIG.2C, each of the one or more pump modules150can further comprise guarding114, such as configured for rotating or otherwise moving one or more components of the pump module150; deflectors, trays, and/or tanks117, such as for directing or containing fluids; or a combination thereof.

The electric motor110can comprise a first drive shaft111A and a second drive shaft111B. In such embodiments, as depicted inFIGS.1A-1C, the pumping unit100can comprise two pump modules150, with a first pump module150A and a second pump module150B depicted inFIG.1A. First pump module150A is connected to the first drive shaft111A and second pump module150B is connected to the second drive shaft111B, whereby the two pump modules150can be driven by the single electric motor110. As depicted inFIG.1BandFIG.1C, one pump module150(e.g., pump module150A inFIG.1Band pump module150B inFIG.1C) can be removed from pumping unit100.

As noted hereinabove, the pumping unit100can be designed to operate with a single pump module150or more pump modules150(e.g., with exactly two pump modules150). In embodiments, a pump module designed for operation with one pump module150can also be operated with a single pump module150.

As depicted inFIG.2C, each of the one or more pump modules150can further comprise a pump packing lubrication system151a(e.g., a “packing grease system”), and/or can be connected to a remote pump packing grease system151b, and have no fluid connections from the pump packing lubrication system151to the base structure101.

One or more of the pump module(s)150can comprise a pump life monitoring system154that is operable to provide component identification, data processing, data storage and/or communications (e.g., internal and/or external), or a combination thereof. In this manner, life data for each pump module150can be monitored and tracked (e.g., independently of the life of a pumping unit100itself).

As noted herein, pump120of each pump module150can comprise a triplex or quintuplex plunger pump (e.g., positive displacement pump), in embodiments. Pump120of each of the one or more pump modules150can be mounted onto the pump module structure130of the each of the one or more pump modules150in a manner designed to reduce and/or prevent translation of flexure of the pump module structure130to the pump120. For example, in embodiments, pump120of each of the one or more pump modules150can be mounted onto the pump module structure130of the each of the one or more pump modules150via a three-point mounting sub-structure190that reduces and/or prevents translation of flexure of the pump module structure130to the pump120.

Additionally, or alternatively, pump120of one or more pump modules150can be a centrifugal pump. A centrifugal pump for pumping wellbore servicing fluids downhole comprises a housing having an inlet and an outlet, and a rotating impeller disposed within the housing. The impeller has a plurality of vanes extending radially outwardly from a central hub and is mounted on a shaft that is driven by the electric motor. The impeller rotates at high speed, creating a centrifugal force that propels the wellbore servicing fluid (e.g., fracturing fluid) through the pump and into the wellbore via a manifold and associate piping fluidically coupling the pump120to the wellbore.

Each of the one or more pump modules150is driven by the electric motor110via connection of a driveline135of each of the pump modules150with a shaft111of the electric motor110. In embodiments, the driveline can comprise a driveshaft clutch and/or a driveshaft decoupler152, whereby rotary motion can be prevented from being transmitted from the electric motor110to pump120. Such a driveshaft clutch and/or a driveshaft decoupler152is disclosed, for example, in U.S. patent application Ser. No. 18/150,478, the disclosure of which is hereby incorporated herein in its entirety for purposes not contrary to this disclosure.

As best seen inFIG.2BandFIG.2D, the pumping unit100can further comprise a gear box/speed reducer180positioned on or near the pump120(e.g., operatively connected with a driveline135of the pump120of each of the one or more pump modules150), and configured to reduce input speed to electric motor110. With reference toFIG.4B, which is a close-up of another portion of a pumping unit100comprising gear box/speed reducer180, in embodiments, the pump module150further comprises a sound blanket185on the gear box/speed reducer180, to reduce noise emanation therefrom.

Also disclosed herein is a method comprising: transporting a modularized, electric pumping unit100, of this disclosure. The pumping unit100can be a pumping unit100as described herein. For example, the pumping unit100can comprise: a base structure assembly105comprising: a base structure101, an electric motor110, an electric motor drive160, an auxiliary electric power supply107, or a combination thereof mounted to the base structure101; and one or more pump modules150, wherein each of the one or more pump modules150is configured for mounting on the base structure101and connection to the electric motor110, whereby a pump110of each of the one or more pump modules150can be driven by the electric motor110, and wherein all of the one or more pump modules150are not mounted on the base structure101during the transporting of the pumping unit100(e.g., one or more of the pump modules150are removed from the base structure101prior to transport).

The method can further comprise assembling the (modularized, electric) pumping unit100after the transporting. Assembling can comprise mounting the one or more pump modules150on the base structure101and operatively connecting each of the one or more pump modules150to the electric motor110.

Operatively connecting can further comprise, for each of the one or more pump modules150: engaging one or more lifting components113of the each pump module150with a lifting apparatus112(e.g., a forklift) and positioning the each pump module150on the base structure101such that one or more of the mounting elements115of the base structure101engage/align with the one or more complementary mounting elements116of the each pump module150, thus affixing a pump module structure130of the each pump module150to the base structure101; and connecting one or more electrical cables and/or hoses104of the each pump module150to connectors103of a connector panel102on the base structure101of the pumping unit150; and connecting a driveline135of the each pump module150to the electric motor110.

The method can further include removing one or more of the pump modules150(to a dis-assembled configuration of the pumping unit100, for example as depicted inFIG.1B-FIG.1D) from an assembled configuration (e.g.,FIG.1A) of the pumping unit100prior to the transporting. Removing the one or more pump modules150from the assembled configuration of the pumping unit100can further comprise, for each of the one or more pump modules150: disconnecting a driveline135of the each pump module150from the electric motor110; unplugging electrical cables and/or hoses104from connectors103on the base structure101; releasing complementary mounting elements116affixing a pump module structure130of the each pump module150to the base structure101; and lifting the each pump module150off the base structure101.

Lifting the each pump module150off the base structure101can comprise engaging one or more lifting components/points113on the pump module structure130of the each pump module150with a lifting apparatus112, and utilizing the lifting apparatus112to lift the each pump module150off the base structure101. As depicted inFIG.5, which is a schematic of a pump module150according to embodiments of this disclosure being transported, the lifting apparatus112can comprise a forklift, and the lifting components/points113can comprise one or more forklift pockets113, whereby the forklift112can engage the forklift pockets to lift the pump module150off the base structure101.

Also disclosed herein are a method of servicing a wellbore and a wellbore servicing system200comprising one or more pumping units100of this disclosure. An embodiment of a wellbore servicing system200and a method of servicing a wellbore via the wellbore servicing system200will now be described with reference toFIG.6, which is a schematic representation of an embodiment of a wellbore servicing system200, according to embodiments of this disclosure. For simplicity and clarity, components of pumping units100and pump modules150other than pumps120and electric motors110have been omitted fromFIG.6.

A method of servicing a wellbore224according to this disclosure can comprise fluidly coupling a pump120of a pump module150of a pumping unit100of this disclosure, as described hereinabove, to a source of a wellbore servicing fluid (e.g., a wellbore services manifold trailer204) and to the wellbore224, and communicating wellbore servicing fluid into the wellbore224via the pump120. The pump120can comprise a pump fluid end and a pump power end. The pump power end is operable to reciprocate a reciprocating element within a reciprocating element bore of the pump fluid end.

The method of servicing the wellbore can comprise connecting a fluid inlet (e.g., suction or suction manifold148) on each of the one or more pump modules150to a source of a wellbore servicing fluid (e.g., a wellbore services manifold trailer204), connecting a fluid outlet (e.g., outlet or discharge manifold149) on each of the one or more pump modules150to a well, and operating each of the one or more pump modules150via the electric motor110to pump the wellbore servicing fluid (e.g., fracturing fluid) into the wellbore224and surrounding formation (e.g., to fracture the subterranean formation). The method can further comprise recovering oil and/or gas (e.g., hydrocarbons) from the wellbore224(e.g., flowing to the wellbore via the fractured subterranean formation).

It will be appreciated that the wellbore servicing system200disclosed herein can be used for any purpose. In embodiments, the wellbore servicing system200may be used to service a wellbore224that penetrates a subterranean formation by pumping a wellbore servicing fluid into the wellbore and/or subterranean formation. As used herein, a “wellbore servicing fluid” or “servicing fluid” refers to a fluid used to drill, complete, work over, fracture, repair, or in any way prepare a well bore for the recovery of materials residing in a subterranean formation penetrated by the well bore. It is to be understood that “subterranean formation” encompasses both areas below exposed earth and areas below earth covered by water such as ocean or fresh water. Examples of servicing fluids suitable for use as the wellbore servicing fluid, the another wellbore servicing fluid, or both include, but are not limited to, cementitious fluids (e.g., cement slurries), drilling fluids or muds, spacer fluids, fracturing fluids or completion fluids, and gravel pack fluids, remedial fluids, perforating fluids, diverter fluids, sealants, drilling fluids, completion fluids, gelation fluids, polymeric fluids, aqueous fluids, oleaginous fluids, etc.

In embodiments, the wellbore servicing system200comprises one or more pumping units100operable to perform oilfield and/or well servicing operations. The oilfield and/or well servicing operations may include, but are not limited to, drilling operations, fracturing operations, perforating operations, fluid loss operations, primary cementing operations, secondary or remedial cementing operations, or any combination of operations thereof. Although a wellbore servicing system is illustrated, skilled artisans will readily appreciate that the pump10disclosed herein may be employed in any suitable operation. Each of the one or more pumping units100comprises one or a plurality of pump modules150, and each of the one or more pump modules150comprises one or a plurality of pumps120operated by an electric motor110, as detailed hereinabove.

In embodiments, the wellbore servicing system200may be a system such as a fracturing spread for fracturing wells in a hydrocarbon-containing reservoir. In fracturing operations, wellbore servicing fluids, such as particle laden fluids, are pumped at high-pressure into a wellbore. The particle laden fluids may then be introduced into a portion of a subterranean formation at a sufficient pressure and velocity to cut a casing and/or create perforation tunnels and fractures within the subterranean formation. Proppants, such as grains of sand, are mixed with the wellbore servicing fluid to keep the fractures open so that hydrocarbons may be produced from the subterranean formation and flow into the wellbore. Hydraulic fracturing may desirably create high-conductivity fluid communication between the wellbore and the subterranean formation.

For example, the wellbore servicing system200of the embodiment ofFIG.6comprises a blender202that is coupled to a wellbore services manifold trailer204via flowline206. As used herein, the term “wellbore services manifold trailer” can include a truck, trailer, and/or other wellbore servicing fluid source comprising one or more manifolds for receiving, organizing, and/or distributing wellbore servicing fluids during wellbore servicing operations. In the embodiment ofFIG.6, the wellbore services manifold trailer204is coupled to eight positive displacement pumps120via outlet flowlines208(e.g., connected to suction manifolds148of pump module(s)150) and inlet flowlines210(e.g., connected to discharge flow lines149of pump modules150). In alternative embodiments, however, there may be more or less pumps used in a wellbore servicing operation. Outlet flowlines208are outlet lines from the wellbore services manifold trailer204that supply fluid to the pumps120. Inlet flowlines210are inlet lines from the pumps120that supply fluid to the wellbore services manifold trailer204. One or more (e.g., two adjacent) pumps120can be mounted on a module150. One or more modules150can be positioned on a base structure101of a pumping unit100. The pumps120and pump modules can be mounted to a base structure101(e.g., a trailer) for transportation to the wellsite via, for example, a semi-tractor, or the pump modules150and the base structure assembly105can be transported separately, as described hereinabove.

The blender202can be utilized/operable to mix or otherwise combine solid and fluid components of the wellbore servicing fluid to achieve a well-blended wellbore servicing fluid. As depicted, in embodiments, sand or proppant212, water214, and/or additives216can be fed into the blender202via feedlines218,220, and212, respectively. The water214may be potable, non-potable, untreated, partially treated, or treated water. In embodiments, the water214may be produced water that has been extracted from the wellbore while producing hydrocarbons form the wellbore. The produced water may comprise dissolved and/or entrained organic materials, salts, minerals, paraffins, aromatics, resins, asphaltenes, and/or other natural or synthetic constituents that are displaced from a hydrocarbon formation during the production of the hydrocarbons. In embodiments, the water214may be flowback water that has previously been introduced into the wellbore during wellbore servicing operation. The flowback water may comprise some hydrocarbons, gelling agents, friction reducers, surfactants and/or remnants of wellbore servicing fluids previously introduced into the wellbore during wellbore servicing operations.

The water214may further comprise local surface water contained in natural and/or manmade water features (such as ditches, ponds, rivers, lakes, oceans, etc.). Still further, the water214may comprise water stored in local or remote containers. The water214may be water that originated from near the wellbore and/or may be water that has been transported to an area near the wellbore from any distance. In some embodiments, the water214may comprise any combination of produced water, flowback water, local surface water, and/or container stored water. In some implementations, water may be substituted by nitrogen or carbon dioxide; some in a foaming condition.

In embodiments, the blender202may be an Advanced Dry Polymer (ADP) blender and the additives216are dry blended and dry fed into the blender202. In alternative embodiments, however, additives may be pre-blended with water using other suitable blenders, such as, but not limited to, a GEL PRO blender, which is a commercially available preblender trailer from Halliburton Energy Services, Inc., to form a liquid gel concentrate that may be fed into the blender202. The mixing conditions of the blender202, including time period, agitation method, pressure, and temperature of the blender202, may be chosen by one of ordinary skill in the art with the aid of this disclosure to produce a homogeneous blend having a desirable composition, density, and viscosity. In alternative embodiments, however, sand or proppant, water, and additives may be premixed and/or stored in a storage tank before entering a wellbore services manifold trailer204.

In embodiments, the pump(s)120pressurize the wellbore servicing fluid to a pressure suitable for delivery into a wellbore224or wellhead. For example, the pumps120can increase the pressure of the wellbore servicing fluid to a pressure of greater than or equal to about 3,000 psi, 5,000 psi, 10,000 psi, 20,000 psi, 30,000 psi, 40,000 psi, or 50,000 psi, or higher, in embodiments.

From the pumps120, the wellbore servicing fluid may reenter the wellbore services manifold trailer204via inlet flowlines210and be combined so that the wellbore servicing fluid may have a total fluid flow rate that exits from the wellbore services manifold trailer204through flowline226to the flow connector wellbore1128of between about 1 BPM to about 200 BPM, alternatively from between about 50 BPM to about 150 BPM, alternatively about 100 BPM. In embodiments, pumps120discharge wellbore servicing fluid at a fluid flow rate of between about 1 BPM to about 200 BPM, alternatively from between about 50 BPM to about 150 BPM, alternatively about 100 BPM. In embodiments, the pumps120discharge wellbore servicing fluid at a volumetric flow rate of greater than or equal to about 3, 10, or 20 barrels per minute (BPM), or in a range of from about 3 to about 20, from about 10 to about 20, or from about 5 to about 20 BPM.

Persons of ordinary skill in the art with the aid of this disclosure will appreciate that the flowlines described herein are piping that are connected together for example via flanges, collars, welds, etc. These flowlines may include various configurations of pipe tees, elbows, and the like. These flowlines connect together the various wellbore servicing fluid process equipment described herein.

The pump modules150and pumping units100of this disclosure can provide a number of potential features and advantages, which will be apparent to those of skill in the art upon reading this disclosure. For example, via this disclosure a pump (e.g., pump120) and related auxiliary equipment (e.g., pump auxiliary systems140and etc., as described hereinabove and depicted in the Figures) can be mounted on a frame (e.g., pump module structure130) that is removable from the main unit base structure (e.g., base structure101). In one embodiment, two pump modules150can be mounted on a trailer (e.g., when base structure101comprises a trailer) and driven by a single electric motor (e.g., electric motor110). The motor (e.g., motor110) and its drive (e.g., variable frequency electric drive160), as well as connection points (e.g., connector panel102) for the pump module150electric cables and fluid hoses104, can remain on the base structure (e.g., base structure101). Via this disclosure, the electrically-driven modular pump system can be mounted on a base structure101that has connection points (e.g., connectors103on connector panel102) for related cables and/or hoses104.

In embodiments, the pumping unit100of this disclosure can facilitate transportation of high-power-density electric fracturing units from one location to another, can reduce capital requirement per spread, and/or can improve maintenance efficiency and effectiveness. The herein disclosed pumping unit100can provide for electric fracturing service with near- or fully-self-contained auxiliary systems.

The pumping units100of this disclosure can comprise electric drive (e.g., electric drive160and electric motor110). The pumping units100of this disclosure do not include electrical or fluid couplers mounted to the module/section frame (e.g., to the pump module structure130); rather, via this disclosure, such electrical or fluid couplers (e.g. connector panel102and/or connectors103) are mounted (e.g., directly) to base structure101.

ADDITIONAL DISCLOSURE

In a first embodiment a (modularized, electric) pumping unit100comprises: a base structure101; an electric motor110mounted on the base structure101; and one or more pump modules150, each of the one or more pump modules comprising a pump120and a pump module structure130, wherein the one or more pump modules150are configured to be removably mounted on the base structure101and driven by the electric motor110.

A second embodiment can include the pumping unit of the first embodiment further comprising at least one connector panel102affixed to the base structure101and comprising connectors103for electrical cables and/or hoses104from the one or more pump modules150, wherein the electrical cables and/or hoses104are configured for supplying fluids, electric power, and/or control signals to the one or more pump modules150, and/or to receive sensor feedback from the one or more pump modules150.

A third embodiment can include the pumping unit of the first or the second embodiment, wherein the base structure101comprises a truck, a trailer, or a skid.

A fourth embodiment can include the pumping unit of any one of the first to third embodiments, comprising a base structure assembly105comprising the base structure101, the electric motor110, an electric motor drive, an auxiliary electric power supply107, or a combination thereof (e.g., mounted on the base structure101).

A fifth embodiment can include the pumping unit of any one of the first to fourth embodiments, further comprising a pump packing lubrication system108mounted on the base structure101.

A sixth embodiment can include the pumping unit of any one of the first to fifth embodiments, wherein the base structure101further comprises one or more mounting points115, and wherein each of the one or more pump modules150comprises one or more complementary mounting elements116, wherein each of the one or more mounting points115of the base structure101are configured to receive/align with one or more of the one or more complementary mounting elements116of the one or more pump modules150, to position and/or align the pump module150(e.g., a driveline135thereof) with the electric motor110(e.g., with a motor shaft111thereof).

A seventh embodiment can include the pumping unit of any one of the first to sixth embodiments, wherein each of the one or more pump modules150comprises the pump module structure130, the pump120, a driveline135, and pump auxiliary systems140.

An eighth embodiment can include the pumping unit of the seventh embodiment, wherein the pump auxiliary systems140further comprise an oil lubrication pump141, (e.g., powered by an auxiliary electric motor142), an oil reservoir143, one or more oil filters144, and oil cooler145(e.g., comprising a heat exchanger145′ and a fan145″), a sensor package146(e.g., comprising one or more sensors147for monitoring pressure, temperature, position, or the like), a driveline135(“driveshaft assembly”), or a combination thereof.

A ninth embodiment can include the pumping unit of any one of the first to eighth embodiments, wherein the pump auxiliary systems140further comprise a suction manifold148and a discharge manifold149with connectors for piping, a pump packing lubrication system151, a driveshaft clutch and/or driveshaft decoupler152, electrical cables104, control systems153, or a combination thereof.

A tenth embodiment can include the pumping unit of any one of the first to ninth embodiments, wherein each of the pump modules150comprises cables and/or hoses104that extend to one or more connector panels102mounted on the base structure101.

An eleventh embodiment can include the pumping unit of any one of the first to ninth embodiments, wherein each of the one or more pump modules150further comprises lift components113configured for removal of each of the one or more pump modules150from the base structure101.

A twelfth embodiment can include the pumping unit of the eleventh embodiment, wherein the lifting components113comprise forklift pockets, lifting eyes, or a combination thereof.

A thirteenth embodiment can include the pumping unit of any one of the first to twelfth embodiments, wherein each of the one or more pump modules150further comprises guarding114configured for rotating or otherwise moving one or more components of the pump module150, deflectors, trays, and/or tanks117for directing or containing fluids, or a combination thereof.

A fourteenth embodiment can include the pumping unit of any one of the first to thirteenth embodiments, wherein the electric motor110comprises a first drive shaft111A and a second drive shaft111B (e.g., extending horizontally in opposite directions from the electric motor), and wherein the pumping unit100comprises two pump modules150, a first pump module150A connected to the first drive shaft111A and a second pump module150B connected to the second drive shaft111B, whereby the two pump modules150are driven by the electric motor110.

A fifteenth embodiment can include the pumping unit of any one of the first to fourteenth embodiments, comprising a single pump module150or comprising exactly two pump modules150.

A sixteenth embodiment can include the pumping unit of any one of the first to fifteenth embodiments, wherein each of the one or more pump modules150further comprises a pump packing lubrication system151(e.g., a “packing grease system”), and/or are connected to a remote pump packing grease system151, and no fluid connections of the pump packing lubrication system are mounted to the base structure101.

A seventeenth embodiment can include the pumping unit of any one of the first to sixteenth embodiments, wherein one or more of the one or more pump modules150comprise a pump life monitoring system154that includes component identification, data processing, data storage and communications (e.g., internal and/or external), or a combination thereof.

An eighteenth embodiment can include the pumping unit of any one of the first to seventeenth embodiments, wherein each of the one or more pump modules150comprises a triplex or quintuplex plunger pump.

A nineteenth embodiment can include the pumping unit of any one of the first to eighteenth embodiments, wherein the pump120of each of the one or more pump modules150is mounted onto the pump module structure130of the each of the one or more pump modules150via a three-point mounting sub-structure190that reduces and/or prevents translation of flexure of the pump module structure130to the pump120.

A twentieth embodiment can include the pumping unit of any one of the first to nineteenth embodiments, wherein each of the one or more pump modules150is driven by the electric motor110via connection of a driveline135of each of the pump modules150with a shaft111of the electric motor110, and wherein the driveline135comprises a driveshaft clutch and/or a driveshaft decoupler152.

A twenty first embodiment can include the pumping unit of any one of the first to twentieth embodiments, further comprising a gear box/speed reducer180positioned on or near the pump (e.g., operatively connected with a driveline135of the pump of each of the one or more pump modules150), and configured to reduce an input speed to the electric motor110.

A twenty second embodiment can include the pumping unit of any one of the first to twenty first embodiments, further comprising a sound blanket185on the gear box/speed reducer180.

In a twenty third embodiment, a method comprises: transporting a (modularized, electric) pumping unit100, wherein the pumping unit100comprises: a base structure assembly105comprising: a base structure101, and an electric motor110, an electric motor drive106, an auxiliary electric power supply107, or a combination thereof mounted to/supported by the base structure101; and one or more pump modules150, wherein each of the one or more pump modules150is configured for mounting on the base structure101and connection to the electric motor110, whereby a pump110of each of the one or more pump modules150can be driven by the electric motor110, and wherein the one or more pump modules150are not mounted on the base structure101during the transporting of the pumping unit100.

A twenty fourth embodiment can include the method of the twenty third embodiment, further comprising assembling the (modularized, electric) pumping unit100after the transporting (e.g., at a jobsite such as a wellsite or well pad), wherein assembling comprises mounting the one or more pump modules150on the base structure101and operatively connecting each of the one or more pump modules150to the electric motor110.

A twenty fifth embodiment can include the method of the twenty fourth embodiment, wherein operatively connecting further comprises, for each of the one or more pump modules150: engaging one or more lifting components113of the each pump module150with a lifting apparatus112(e.g., a forklift) and positioning the each pump module150on the base structure101such that one or more of the mounting elements115of the base structure101engage/align with the one or more complementary mounting elements116of the each pump module150, thus affixing a pump module structure130of the each pump module150to the base structure101; and connecting one or more electrical cables and/or hoses104of the each pump module150to connectors103of a connector panel102on the base structure101of the pumping unit150; and connecting a driveline135of the each pump module150to the electric motor110.

A twenty sixth embodiment can include the method of any one of the twenty third to the twenty fifth embodiments, further comprising removing one or more of the pump modules150from an assembled configuration of the pumping unit100prior to the transporting.

A twenty seventh embodiment can include the method of the twenty sixth embodiment, wherein removing the one or more pump modules150from the assembled configuration of the pumping unit100further comprises, for each of the one or more pump modules150: disconnecting a driveline135of the each pump module150from the electric motor110; unplugging electrical cables and/or hoses104from connectors103on the base structure101; releasing complementary mounting elements116affixing a pump module structure130of the each pump module150to the base structure101; and lifting the each pump module150off the base structure101.

A twenty eighth embodiment can include the method of the twenty seventh embodiment, wherein lifting the each pump module150off the base structure101comprises engaging one or more lifting components/points113on the pump module structure130of the each pump module150with a lifting apparatus112(e.g., a forklift), and utilizing the lifting apparatus112to lift the each pump module150off the base structure101.

In a twenty ninth embodiment, a pump module150comprises a pump120affixed to a pump module structure130, a driveline135operatively connected to the pump120, and pump auxiliary systems140, wherein the pump module150is configured to be removably mounted on a base structure101of a pumping unit100and driven by an electric motor affixed to the base structure101.

A thirtieth embodiment can include the pump module150of the twenty ninth embodiment, wherein the pump auxiliary systems140further comprise an oil lubrication pump141, (e.g., powered by an auxiliary electric motor142), an oil reservoir143, one or more oil filters144, and oil cooler145(e.g., comprising a heat exchanger145′ and a fan145″), a sensor package146(e.g., comprising one or more sensors147for monitoring pressure, temperature, position), a driveline135, or a combination thereof.

A thirty first embodiment can include the pump module150of the twenty ninth or thirtieth embodiment, wherein the base structure further comprises at least one connector panel102affixed to the base structure and comprising connectors103for electrical cables and/or hoses104from the pump module150, wherein the electrical cables and/or hoses104are configured for supplying fluids, electric power, and/or control signals to the pump module, and/or to receive sensor feedback from the pump module, and wherein the pump module does not comprise such a connector panel thereon.

A thirty second embodiment can include the pump module150of any one of the twenty ninth to thirty first embodiments, wherein the pump120of the pump module150is mounted onto the pump module structure130via a three-point mounting sub-structure190that reduces and/or prevents translation of flexure of the pump module structure130to the pump120.

A thirty third embodiment can include the pump module150of any one of the twenty ninth to thirty second embodiments, further comprise a pump life monitoring system154that includes component identification, data processing, data storage and/or communications (e.g., internal and/or external), or a combination thereof.

A thirty fourth embodiment can include the pump module150of any one of the twenty ninth to thirty third embodiments, further comprising a gear box/speed reducer180positioned on or near the pump (e.g., operatively connected with a driveline135of the pump), and configured to reduce input speed to the electric motor110, when the pump module150is operatively connected with the electric motor110, and the electric motor110is in operation.

A thirty fifth embodiment can include the pump module150of the thirty fourth embodiment, further comprising a sound blanket185on the gear box/speed reducer180.

A thirty sixth embodiment can include the method of any of twenty fourth or twenty fifth embodiments, further comprising connecting a fluid inlet on each of the one or more pump modules to a source of a wellbore servicing fluid, connecting a fluid outlet on each of the one or more pump modules to a well penetrating a subterranean formation, and operating each of the one or more pump modules via the electric motor to pump the wellbore servicing fluid (e.g., fracturing fluid) into the well and surrounding formation (e.g., to fracture the subterranean formation), and optionally further comprising recovering oil and/or gas (e.g., hydrocarbons) from the well (e.g., flowing to the well via the fractured subterranean formation).

While embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of this disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the embodiments disclosed herein are possible and are within the scope of this disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R1, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R1+k*(Ru−R1), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc. When a feature is described as “optional,” both embodiments with this feature and embodiments without this feature are disclosed. Similarly, the present disclosure contemplates embodiments where this “optional” feature is required and embodiments where this feature is specifically excluded.

As used herein, the term “and/or” includes any combination of the elements associated with the “and/or” term. Thus, the phrase “A, B, and/or C” includes any of A alone, B alone, C alone, A and B together, B and C together, A and C together, or A, B, and C together.