Fluid delivery device for a hydraulic fracturing system

A syringe assembly for a hydraulic fracturing system includes a syringe having a material chamber, a base fluid chamber, and a piston. The material chamber is configured to be fluidly connected to a fluid conduit. The piston retracts to draw material into the material chamber. The piston extends to push the material into the fluid conduit. The syringe assembly includes a diverter fluidly connected to the base fluid chamber and moveable between first and second positions. The first position of the diverter fluidly connects the base fluid chamber to a base fluid reservoir of the hydraulic fracturing system and fluidly disconnects the base fluid chamber from an outlet of a frac pump of the hydraulic fracturing system. The second position of the diverter fluidly connects the base fluid chamber to the outlet of the frac pump and fluidly disconnects the base fluid chamber from the base fluid reservoir.

TECHNICAL FIELD

This disclosure relates to hydraulic fracturing systems, and in particular, to fluid delivery devices for hydraulic fracturing systems.

BACKGROUND OF THE DISCLOSURE

In oilfield operations, reciprocating pumps are used for different fracturing operations such as fracturing subterranean formations to drill for oil or natural gas, cementing a wellbore, or treating the wellbore and/or formation. A reciprocating pump designed for fracturing operations is sometimes referred to as a “frac pump.” A reciprocating pump typically includes a power end and a fluid end (sometimes referred to as a cylindrical section). The fluid end is typically formed of a one piece construction or a series of blocks secured together by rods. The fluid end includes a fluid cylinder having a plunger passage for receiving a plunger or plunger throw, an inlet passage that holds an inlet valve assembly, and an outlet passage that holds an outlet valve assembly.

Conventional systems used for hydraulic fracturing consist of a blender that mixes a base fluid (e.g., water, liquefied petroleum gas (LPG), propane, etc.) with one or more other materials (e.g., a slurry, sand, acid, proppant, a sand and base fluid mixture, a gel, a foam, a compressed gas, etc.) to form a fracturing fluid, which is sometimes referred to as a “fracking fluid.” The fracking fluid is transported to the fluid end of the frac pump via a low-pressure line. The fluid end of the frac pump pumps the fracking fluid to the well head via a high-pressure line. Thus, the fluid end of the frac pump is currently the point of transition of the fracking fluid from low pressure to high pressure in the hydraulic fracturing system. Specifically, the fluid end brings the fracking fluid in from the low-pressure line and forces it out into the high-pressure line. The fracking fluid often contains solid particulates and/or corrosive material such that the fracking fluid can be relatively abrasive.

Over time, the flow of the abrasive fracking fluid through the fluid end of the frac pump can erode and wear down the interior surfaces (e.g., the various internal passages, etc.) and/or the internal components (e.g., valves, seats, springs, etc.) of the fluid end, which can eventually cause the fluid end of the frac pump to fail. Failure of the fluid end of a frac pump can have relatively devastating repercussions and/or can be relatively costly.

SUMMARY

In a first aspect, a syringe assembly for a hydraulic fracturing system is provided. The syringe assembly includes a syringe having a material chamber, a base fluid chamber, and a piston. The material chamber is configured to be fluidly connected to a fluid conduit of the hydraulic fracturing system. The piston is configured to retract to draw at least one material into the material chamber. The piston is configured to extend to push the at least one material into the fluid conduit. The syringe assembly includes a diverter fluidly connected to the base fluid chamber and moveable between first and second positions. The first position of the diverter is configured to fluidly connect the base fluid chamber to a base fluid reservoir of the hydraulic fracturing system and fluidly disconnect the base fluid chamber from an outlet of a frac pump of the hydraulic fracturing system. The second position of the diverter is configured to fluidly connect the base fluid chamber to the outlet of the frac pump and fluidly disconnect the base fluid chamber from the base fluid reservoir.

In one embodiment, the second position of the diverter is configured to approximately equalize the pressure of the base fluid chamber and the material chamber of the syringe.

In some embodiments, the second position of the diverter is configured to increase the pressure of fluid contained within the base fluid chamber of the syringe. The first position of the diverter is configured to release fluid from the base fluid chamber.

In some embodiments, the diverter includes first and second valves. The first valve is open and the second valve is closed in the first position of the diverter. The first valve is closed and the second valve is open in the second position of the diverter.

In some embodiments, the diverter includes a rod and first and second valves held on the rod. The rod reciprocates between the first and second positions of the diverter to open and close the first and second valves.

In some embodiments, the diverter includes a hydraulic actuator configured to move the diverter between the first and second positions.

In one embodiment, the diverter includes a spool valve configured to move the diverter between the first and second positions.

In some embodiments, the syringe includes an actuator configured to extend the piston.

In some embodiments, the syringe includes an actuator configured to extend the piston when the diverter is in the second position.

In a second aspect, a fluid delivery device is provided for a hydraulic fracturing system. The fluid delivery device includes a fluid conduit having a fracking fluid outlet configured to be fluidly connected to a well head for delivering a fracking fluid to the well head. The fluid conduit includes a base fluid inlet configured to be fluidly connected to an outlet of a frac pump of the hydraulic fracturing system. The fluid delivery device includes a syringe having a material chamber fluidly connected to the fluid conduit downstream from the frac pump. The material chamber is configured to be fluidly connected to a material source. The syringe includes a base fluid chamber. The syringe includes a piston that is configured to retract to draw at least one material of the fracking fluid into the material chamber from the material source. The piston is configured to extend to push the at least one material of the fracking fluid from the material chamber into the fluid conduit. The fluid delivery device includes a diverter fluidly connected to the base fluid chamber and moveable between first and second positions. The first position of the diverter is configured to fluidly connect the base fluid chamber to a base fluid reservoir of the hydraulic fracturing system and fluidly disconnect the base fluid chamber from the outlet of the frac pump. The second position of the diverter is configured to fluidly connect the base fluid chamber to the outlet of the frac pump and fluidly disconnect the base fluid chamber from the base fluid reservoir.

In some embodiments, the second position of the diverter is configured to approximately equalize the pressure of the base fluid chamber and the material chamber of the syringe.

In some embodiments, the diverter includes a rod and first and second valves held on the rod. The rod reciprocates between the first and second positions of the diverter to open and close the first and second valves.

In some embodiments, the diverter includes a hydraulic actuator configured to move the diverter between the first and second positions.

In some embodiments, the syringe includes an actuator configured to extend the piston.

In a third aspect, a method is provided for operating a syringe of a hydraulic fracturing system. The method includes fluidly connecting a base fluid chamber of the syringe with a base fluid reservoir to thereby draw at least one material of a fracking fluid into a material chamber of the syringe; fluidly connecting the base fluid chamber of the syringe with an outlet of a frac pump of the hydraulic fracturing system to approximately equalize the pressure within the base fluid chamber and the material chamber; and actuating the syringe to inject the at least one material from the material chamber into a fluid conduit when the base fluid chamber of the syringe is fluidly connected to the outlet of the frac pump.

In some embodiments, fluidly connecting the base fluid chamber of the syringe with the base fluid reservoir includes fluidly connecting the base fluid chamber to a lower pressure line, and fluidly connecting the base fluid chamber of the syringe with the outlet of the frac pump includes fluidly connecting the base fluid chamber to a higher pressure line.

In some embodiments, fluidly connecting the base fluid chamber of the syringe with the base fluid reservoir includes moving a diverter to a first position wherein a first valve of the diverter is open and a second valve of the diverter is closed, and fluidly connecting the base fluid chamber of the syringe with the outlet of the frac pump includes moving the diverter to a second position wherein the second valve is open and the first valve is closed.

In some embodiments, fluidly connecting the base fluid chamber of the syringe with the base fluid reservoir includes retracting a piston of the syringe, and actuating the syringe to inject the at least one material from the material chamber into the fluid conduit when the base fluid chamber is fluidly connected to the outlet of the frac pump includes extending the piston using an actuator of the syringe.

In some embodiments, fluidly connecting the base fluid chamber of the syringe with the base fluid reservoir includes fluidly disconnecting the base fluid chamber of the syringe from the outlet of the frac pump, and fluidly connecting the base fluid chamber of the syringe with the outlet of the frac pump includes fluidly disconnecting the base fluid chamber of the syringe from the base fluid reservoir.

In some embodiments, actuating the syringe to inject the at least one material from the material chamber into the fluid conduit when the base fluid chamber is fluidly connected to the outlet of the frac pump includes injecting the at least one material into the fluid conduit downstream from the frac pump.

Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of the inventions disclosed.

DETAILED DESCRIPTION

Certain embodiments of the disclosure provide a syringe assembly for a fluid delivery system that includes a syringe and a diverter that is fluidly connected to the base fluid chamber and is moveable between first and second positions. The first position of the diverter is configured to fluidly connect a base fluid chamber of the syringe to a base fluid reservoir of a hydraulic fracturing system and fluidly disconnect the base fluid chamber from an outlet of a frac pump of the hydraulic fracturing system. The second position of the diverter is configured to fluidly connect the base fluid chamber to the outlet of the frac pump and fluidly disconnect the base fluid chamber from the base fluid reservoir.

Certain embodiments of the disclosure provide a method for operating a syringe of a hydraulic fracturing system that includes fluidly connecting a base fluid chamber of the syringe with a base fluid reservoir to thereby draw at least one material of a fracking fluid into a material chamber of the syringe; fluidly connecting the base fluid chamber of the syringe with an outlet of a frac pump of the hydraulic fracturing system to approximately equalize the pressure within the base fluid chamber and the material chamber; and actuating the syringe to inject the at least one material from the material chamber into a fluid conduit when the base fluid chamber of the syringe is fluidly connected to the outlet of the frac pump.

Certain embodiments of the disclosure can mitigate the amount of relatively abrasive material that flows through the fluid end of a frac pump by introducing relatively abrasive material into a hydraulic fracturing system after the fluid end of a frac pump (i.e., downstream from the outlet of the frac pump). In some examples, the fluid end of a frac pump will pump a relatively non-abrasive base fluid (e.g., water) exclusively. Certain embodiments of the disclosure reduce wear and erosion on the interior surfaces (e.g., the various internal passages, etc.) and/or the internal components (e.g., valves, seats, springs, etc.) of the fluid end of a frac pump. Certain embodiments of the present disclosure increase (i.e., extend) the longevity and thus the operational life of the fluid ends of frac pumps.

The fluid delivery systems, syringe assemblies, and operational methods disclosed by certain embodiments herein that introduce relatively abrasive materials of a fracking fluid after the fluid end of a frac pump can provide numerous benefits over conventional systems used for hydraulic fracturing, for example the following benefits, without limitation: a fluid end of a frac pump that wears significantly less due to the lack of relatively abrasive material flowing through the fluid end; internal surfaces and/or components of a fluid end that wear significantly less due to the lack of relatively abrasive material flowing through the fluid end; gates of a hydraulic fracturing system will take on significant wear instead of the fluid end of a frac pump; and the fluid end of a frac pump will resist failure for a longer period of time.

FIG. 1is a schematic diagram of a hydraulic fracturing system100according to an exemplary embodiment. The hydraulic fracturing system100is used to pump a fracking fluid into the well head102of a wellbore (not shown) for performing a fracturing operation, for example fracturing a subterranean formation to drill for oil or natural gas, cementing the wellbore, treating the wellbore and/or formation, etc. The hydraulic fracturing system100includes a frac pump104, one or more base fluid sources106, an optional missile108, one or more material sources110, a blender112, and a fluid delivery device114. Although only one is shown inFIG. 1, the hydraulic fracturing system100can include any number of the fluid delivery devices114.

The base fluid source106includes a tank, reservoir, and/or other container that holds a base fluid of the fracking fluid. As will be described below, the base fluid is mixed with one or more other materials to form the fracking fluid. The base fluid of the base fluid source106can be any fluid that is relatively non-abrasive, for example, water, liquefied petroleum gas (LPG), propane, and/or the like. In some examples, the base fluid is relatively non-corrosive. Although only one is shown inFIG. 1, the hydraulic fracturing system100can include any number of the base fluid sources106. According to some embodiments, one or more of the base fluid sources106is freestanding on the ground, mounted to a trailer for towing between operational sites, mounted to a skid, loaded on a manifold, otherwise transported, and/or the like.

The frac pump104includes a power end portion116and a fluid end portion118operably coupled thereto. The power end portion116includes a crankshaft (not shown) that is driven by an engine or motor120. The fluid end portion118includes a fluid end block or fluid cylinder122that includes an inlet124fluidly connected to the base fluid source106and an outlet126fluidly connected to the fluid delivery device114(e.g., via the missile108as described below). In operation, the engine or motor120turns the crankshaft, which reciprocates a plunger rod assembly (not shown) between the power end portion116and the fluid end portion118to thereby pump (i.e., move) a flow of the base fluid from the base fluid source106into the inlet124, through the fluid cylinder122, and out the outlet126to the fluid delivery device114(e.g., via the missile108as described below). Thus, the inlet124defines a lower-pressure side of the frac pump104while the outlet126defines a higher-pressure side of the frac pump104. In some examples, the frac pump104is freestanding on the ground, mounted to a trailer for towing between operational sites, mounted to a skid, loaded on a manifold, otherwise transported, and/or the like. Although only a single frac pump104is shown inFIG. 1, the hydraulic fracturing system100can include any number of frac pumps104.

The missile108is a fluid manifold that is fluidly connected between the frac pump104and the fluid delivery device114for delivering the base fluid from the frac pump104to the fluid delivery device114. More particularly, the missile108includes an inlet128fluidly connected to the outlet126of the frac pump104and an outlet130fluidly connected to the fluid delivery device114. The missile108can be freestanding on the ground, mounted to a trailer for towing between operational sites, mounted to a skid, loaded on a manifold, otherwise transported, and/or the like. Optionally, the missile108returns fracking fluid that has been pumped into the wellbore by the hydraulic fracturing system100to a tank, reservoir, and/or other container (e.g., the base fluid source106) and/or the frac pump104. For example, a lower-pressure side of the missile108can fluidly connected to the inlet124of the frac pump104. The missile108is sometimes referred to as a “zipper”.

As described above, the missile108is an optional component of the hydraulic fracturing system100. Accordingly, in some embodiments one or more frac pumps104is directly fluidly connected to a corresponding fluid delivery device114. More particularly, the outlet126of a frac pump104of the hydraulic fracturing system100can be directly fluidly connected to a corresponding fluid delivery device114to thereby pump (i.e., move) a flow of the base fluid through the fluid cylinder122and out the outlet126of the frac pump104directly to the fluid delivery device114.

The material source110includes a tank, reservoir, and/or other container that holds one or more materials that are mixed with the base fluid to form the fracking fluid that is delivered to the well head102by the hydraulic fracturing system100. The material(s) held by the material source110can include any material(s) that can be mixed with the base fluid to form a fracking fluid that is suitable for performing a fracturing operation, for example a slurry, sand, acid, proppant, a sand and base fluid mixture, a gel, a foam, a compressed gas, and/or the like. The hydraulic fracturing system100can include any number of the material sources110, each of which can hold any number of different materials. According to some embodiments, one or more of the material sources110is freestanding on the ground, mounted to a trailer for towing between operational sites, mounted to a skid, loaded on a manifold, otherwise transported, and/or the like.

The blender112is configured to deliver a flow of one or more materials from the material source(s)110to the fluid delivery device110. More particularly, the blender112includes an inlet132fluidly connected to the material source(s)110and an outlet134fluidly connected to the fluid delivery device114. The blender112can mix two or more materials from two or more different material sources110together for delivery to the fluid delivery device114. In some examples, the blender112is fluidly connected to a base fluid source106or another source of base fluid for mixing base fluid with one or more materials from one or more material sources110for delivery to the fluid delivery device114. Moreover, in some examples the blender112mixes base fluid (whether from the base fluid source106or another source) with one or more materials from one or more different material sources110to form a finished (i.e., complete) fracking fluid that is ready for delivery to the fluid delivery device114. Optionally, the blender112includes a pump (not shown) and/or other device for delivering the flow of material(s) to the fluid delivery device114.

The blender112can be freestanding on the ground, mounted to a trailer for towing between operational sites, mounted to a skid, loaded on a manifold, otherwise transported, and/or the like. The hydraulic fracturing system100can include any number of blenders112. The blender112and the material source110may each be referred to herein as a “material source”. For example, the “material source” recited in the claims of the present disclosure may refer to the blender112and/or one or more material sources110.

FIG. 2is a schematic diagram of another fluid delivery device214that can be used with the hydraulic fracturing system100(FIG. 1) according to an exemplary embodiment. The fluid delivery device214includes a fluid conduit236and one or more injection systems238. In the exemplary embodiment of the fluid delivery device214, three injection systems238a,238b, and238care provided. But, the fluid delivery device214can include any number of injection systems238. According to some embodiments, the fluid delivery device214is mounted on a trailer, freestanding on the ground, mounted to a skid, loaded on a manifold, otherwise transported, and/or the like.

The fluid conduit236includes a base fluid inlet240, a mixing segment242, and a fracking fluid outlet244. The base fluid inlet240is configured to be fluidly connected to the outlet126(FIG. 1) of the frac pump104(FIG. 1) for receiving the flow of base fluid from the frac pump104. The base fluid inlet240defines a higher-pressure entrance of the fluid delivery device214. For example, the base fluid inlet240defines a higher-pressure inlet of the fluid conduit236that receives the flow of base fluid from the higher-pressure side (i.e., the outlet126) of the frac pump104. The base fluid inlet240can be indirectly fluidly connected to the outlet126of the frac pump104via the missile108(FIG. 1) or can be directly fluidly connected to the outlet126of the frac pump104.

Each injection system238is configured to inject at least one material of the fracking fluid (e.g., from the blender112shown inFIG. 1, directly from one or more material sources110shown inFIG. 1, etc.) into the mixing segment242of the fluid conduit236to generate the fracking fluid within the mixing segment242. The fracking fluid outlet244is configured to be directly or indirectly fluidly connected to the well head102(FIG. 1) for delivering a flow of the fracking fluid to the well head102. The fracking fluid outlet244defines a higher-pressure outlet of the fluid conduit236. Accordingly, the fracking fluid outlet244defines a higher-pressure exit of the fluid delivery device214.

Each injection system238includes a syringe246that includes a material chamber248, a base fluid chamber250, a piston252, and an actuator254. The piston252includes a piston head256that extends within the base fluid chamber250and a piston ram258that extends within the material chamber248. The piston252is configured to move between an extended position and a retracted position such that the piston ram258extends and retracts within the material chamber248, as can be seen inFIG. 2. For example, the piston ram258of the injection system238ais shown inFIG. 2in the retracted position, while the piston ram258of the injection system238bis shown in an extended position inFIG. 2. Operation of the piston252will be described in more detail below.

The actuator254is operatively connected to the piston252such that the actuator254is configured to move the piston252from the extended position to the retracted position. In the exemplary embodiment of the fluid delivery device214, the actuator254is a hydraulic oil pump that is configured to move hydraulic oil into a hydraulic oil chamber260such that the hydraulic oil exerts a force on a side262of the piston head256that moves the piston252from the extended position to the retracted position. The actuator254is not limited to being a hydraulic oil pump, but rather additionally or alternatively can include any type of actuator that is capable of moving the piston252from the extended position to the retracted position, for example an electric motor, a linear actuator (e.g., a ball screw, a lead screw, a rotary screw, a solenoid, etc.), and/or the like.

The material chamber248of the syringe246of each injection system238includes a material inlet264that is fluidly connected to the outlet134(FIG. 1) of the blender112for receiving a flow of at least one material of the fracking fluid from the blender112. The material inlet264defines a lower-pressure entrance of the fluid delivery device214. For example, the material inlet264defines a lower-pressure inlet of the material chamber248. The material inlet264includes a material inlet valve266that controls the flow of material(s) from the blender112through the material inlet264into the material chamber248of the syringe246. Specifically, the material inlet valve266is moveable between an open position and a closed position. The open position of the material inlet valve266enables material(s) to flow from the blender112through the material inlet264into the material chamber248. The closed position of the material inlet valve266prevents material(s) from the blender112from flowing through the material inlet264into the material chamber248.

In the exemplary embodiment of the fluid delivery device214, the material inlet valve266is a check valve that is moved between the open and closed positions via pressure differentials across the valve266, as will be described below. In other examples, movement of the material inlet valve266between the open and closed positions is controlled by the control system of the hydraulic fracturing system100(e.g., based on a position of the piston ram258, based on a predetermined timing scheme, based on a particle count sensor (not shown) within the material chamber248, based on another sensor (not shown) within the material chamber248, etc.). In addition or alternatively to a check valve, the material inlet valve266can include any other type of valve (e.g., an integrated circuit (IC) driven valve, a programmable logic control (PLC) driven valve, another electrically controlled valve, etc.) that enables the hydraulic fracturing system100to function as described and/or illustrated herein.

Although described herein as being indirectly fluidly connected to the material source(s)110via the blender112, the material inlet264of the material chamber248of each syringe246can be directly fluidly connected to one or more of the material sources110for receiving a flow of at least one material of the fracking fluid directly therefrom. Optionally, the material inlets264of the material chambers248include a common entrance (not shown).

The material chamber248of the syringe246of each injection system238includes a material outlet268that is fluidly connected to the mixing segment242of the fluid conduit236. Accordingly, the material outlet268is fluidly connected to the fluid conduit236downstream from the base fluid inlet240and thus downstream from the frac pump104, as is shown herein. The material outlet268defines a higher-pressure outlet of the fluid conduit236. Accordingly, the material outlet268defines a higher-pressure exit of the fluid delivery device214.

The material outlet268includes a material outlet valve270that controls the flow of material(s) from the material chamber248of the syringe246through the material outlet268into the mixing segment242of the fluid conduit236. Specifically, the material outlet valve270is moveable between an open position and a closed position. The open position of the material outlet valve270enables material(s) to flow from the material chamber248through the material outlet268into the mixing segment242of the fluid conduit236. The closed position of the material outlet valve270prevents material(s) from the material chamber248from flowing through the material outlet268into the mixing segment242of the fluid conduit236.

In the exemplary embodiment of the fluid delivery device214, the material outlet valve270is a check valve that is moved between the open and closed positions via pressure differentials across the valve270, as will be described below. In other examples, movement of the material outlet valve270between the open and closed positions is controlled by the control system of the hydraulic fracturing system100(e.g., based on a position of the piston ram258, based on a predetermined timing scheme, based on a particle count sensor within the material chamber248, based on another sensor within the material chamber248, etc.). In addition or alternatively to a check valve, the material outlet valve270can include any other type of valve (e.g., an integrated circuit (IC) driven valve, a programmable logic control (PLC) driven valve, another electrically controlled valve, etc.) that enables the hydraulic fracturing system100to function as described and/or illustrated herein.

The base fluid chamber250of the syringe246of each injection system238includes a base fluid inlet272that is configured to be fluidly connected to the outlet126of the frac pump104for receiving a flow of base fluid from the frac pump104. The base fluid inlet272can be indirectly fluidly connected to the outlet126of the frac pump104via the missile108or can be directly fluidly connected to the outlet126of the frac pump104. The base fluid inlet272defines a higher-pressure entrance of the fluid delivery device214. For example, the base fluid inlet272defines a higher-pressure inlet of the base fluid chamber250. The base fluid inlet272includes a base fluid inlet valve274. The base fluid inlet valve274controls the flow of base fluid into the base fluid chamber250of the syringe246. More particularly, the base fluid inlet valve274is moveable between an open position that enables base fluid to through the base fluid inlet272into the base fluid chamber250and a closed position that prevents base fluid from the frac pump104from flowing through the base fluid inlet272into the base fluid chamber250.

Movement of the base fluid inlet valve274between the open and closed positions can be controlled by the control system of the hydraulic fracturing system100. In some examples, movement of the base fluid inlet valve274between the open and closed positions is based on a position of the piston head256. In other examples, movement of the base fluid inlet valve274between the open and closed positions is based on a predetermined timing scheme, a particle count sensor within the material chamber248, another sensor within the material chamber248, and/or the like. In the exemplary embodiment of the fluid delivery device214, the base fluid inlet valve274is a hydraulic fill valve. But, additionally or alternatively the base fluid inlet valve274can include any other type of valve (e.g., an integrated circuit (IC) driven valve, a programmable logic control (PLC) driven valve, another electrically controlled valve, etc.) that enables the hydraulic fracturing system100to function as described and/or illustrated herein. Optionally, the base fluid inlets272include a common entrance (not shown).

The base fluid chamber250of the syringe246of each injection system238includes a base fluid outlet276for discharging base fluid from the base fluid chamber250during retraction of the piston252. Optionally, the base fluid outlet276is fluidly connected to the inlet124(FIG. 1) of the frac pump104, the inlet128(FIG. 1) of the missile108, and/or one or more of the base fluid sources106for returning base fluid thereto from the base fluid chamber250. The frac pump104, the missile108, and the base fluid source(s)106may each be referred to herein as a “base fluid reservoir”. For example, the “base fluid reservoir” recited in the claims of the present disclosure may refer to the frac pump104, the missile108, and/or one or more base fluid sources106.

The base fluid outlet276defines a lower-pressure exit of the fluid delivery device214. For example, the base fluid outlet276defines a lower-pressure outlet of the base fluid chamber250. The base fluid outlet276includes a base fluid outlet valve278that controls the flow of base fluid out of the base fluid chamber250through the base fluid outlet276. Specifically, the base fluid outlet valve278is moveable between an open position that enables base fluid to flow out of the base fluid chamber250through the base fluid outlet276and a closed position that prevents base fluid from flowing out of the base fluid chamber250through the base fluid outlet276.

In some examples, movement of the base fluid outlet valve278between the open and closed positions is based on a pressure differential across the valve278(e.g., the valve278is a check valve). In other examples, movement of the base fluid outlet valve278between the open and closed positions is based on a predetermined timing scheme, a particle count sensor within the material chamber248, another sensor within the material chamber248, a position of the piston head256, and/or the like. Movement of the base fluid outlet valve278between the open and closed positions can be controlled by the control system of the hydraulic fracturing system100. In the exemplary embodiment of the fluid delivery device214, the base fluid outlet valve278is a hydraulic bleed valve. But, additionally or alternatively the base fluid outlet valve274can include any other type of valve (e.g., an IC driven valve, a PLC driven valve, another electrically controlled valve, etc.) that enables the hydraulic fracturing system100to function as described and/or illustrated herein. Optionally, the base fluid chambers250include a common entrance (not shown).

Operation of the syringe240of the injection system238awill now be described to provide a general understanding of the operation of the fluid delivery device214. The operation of the syringes240of each of the injections systems238is substantially similar such that the operational description of the injection system238ashould be understood as being representative of the operation of the injection systems238band238b.

At the beginning of a cycle, the actuator254moves the piston252to the retracted position thereby creating a lower-pressure suction that opens the material inlet valve266and draws one or more materials of the fracking fluid from the blender112into the material chamber248through the material inlet264. Movement of the piston252toward the retracted position also opens the base fluid outlet valve278such that base fluid within the base fluid chamber250is discharged therefrom through the base fluid outlet276. In the exemplary embodiment, the suction within the material chamber248and/or a bias of the material outlet valve270to the closed position closes (or maintains as closed) the material outlet valve270during retraction of the piston252. The base fluid inlet valve274is also in the closed position during movement of the piston252toward the retracted position.

Once the piston252reaches a fully retracted position, the base fluid outlet valve278closes and the base fluid inlet valve274opens such that base fluid from the outlet126of the frac pump104flows into the base fluid chamber250. The pressure exerted by the flow of base fluid on a side280of the piston head256is effectively greater than the pressure exerted on the opposite side262of the piston head256by the hydraulic oil, which causes the piston252to move from the retracted position to the extended position. As the piston252moves to the extended position, the piston ram258pressurizes the material(s) from the blender112contained within the material chamber248such that the material outlet valve opens270opens and the material(s) contained within the material chamber248discharge (i.e., are injected) into the mixing segment242through the material outlet268to thereby generate the fracking fluid within the mixing segment242for delivery to the well head102through the fracking fluid outlet244. Accordingly, the syringe240injects the material(s) into the fluid conduit236downstream from the frac pump104. In the exemplary embodiment, the pressure within the material chamber248and/or a bias of the material inlet valve266to the closed position closes the material outlet inlet valve266at the onset of extension of the piston252.

Once the material(s) drawn into the material chamber248from the blender112have been discharged into the mixing segment242of the fluid conduit236, the base fluid inlet valve274closes and the actuator254can retract the piston252to repeat the cycle of the syringe246drawing the material(s) from the blender112into the material chamber248and injecting the material(s) into the mixing segment242to generate the fracking fluid within the fluid conduit236.

In some examples, the material(s) injected into the mixing segment242from the material chamber248mix with base fluid flowing through the mixing segment242to form (i.e., generate) the fracking fluid within the mixing segment242. In other examples, the material(s) injected into the mixing segment242from the material chamber248define a finished (i.e., complete) fracking fluid that is ready for delivery to the well head102. Although the fluid delivery device214is described herein as delivering a fracking fluid to the well head102, in other examples the fluid delivery device214can be used to transport, divert, convey, or otherwise move one or more solid materials (e.g., sand, sandstone, ceramic beads, sintered bauxite, aluminum, other oil and gas well stimulation proppant, etc.) to the well head102.

Various parameters of the injection system238can be selected such that the effective pressure exerted on the side280of the piston head256by the base fluid is greater than the pressure exerted on the opposite side262by the hydraulic oil when the base fluid inlet valve274is open, for example the surface area of the side280as compared to the side262, the pressure of the base fluid within the base fluid chamber250created by the frac pump104as compared to the resting pressure the hydraulic oil within the hydraulic oil chamber260, and/or the like.

Using two or more injection systems238(and/or two or more fluid delivery devices214) can enable the fluid delivery device(s)214to deliver a substantially continuous flow of fracking fluid to the well head102during operation of the hydraulic fracturing system100. More particularly, the syringes246of the injection systems238(and/or two or more fluid delivery devices214) can be cycled between injection phases in an offset timing pattern, for example as is shown inFIG. 2. The ability of the fluid delivery device(s)214to deliver a substantially continuous supply of the fracking fluid to the well head102mitigates the potential for base fluid that has not been mixed with any other materials of the fracking fluid to flow into the well head102.

The hydraulic fracturing system100can include any number of the fluid delivery devices214(each of which can include any number of the injection systems238) to facilitate delivering a substantially continuous flow of fracking fluid to the well head102. Non-limiting examples include a fluid delivery device214having two, three, four, five, ten, or twenty injection systems238timed to deliver a substantially continuous flow of fracking fluid to the well head102. Other non-limiting examples include two, three, four, five, ten, or twenty fluid delivery devices214(each of which can include any number of the injection systems238) timed to deliver a substantially continuous flow of fracking fluid to the well head102.

FIG. 3is a perspective view of another fluid delivery device314that can be used with the hydraulic fracturing system100(FIG. 1) according to an exemplary embodiment. The fluid delivery device314includes a fluid conduit336and one or more injection systems338. In the exemplary embodiment of the fluid delivery device314, three injection systems338a,338b, and338care provided. But, the fluid delivery device314can include any number of injection systems338. According to some embodiments, the fluid delivery device314is mounted on a trailer, freestanding on the ground, mounted to a skid, loaded on a manifold, otherwise transported, and/or the like.

The fluid conduit336includes a base fluid inlet340, a mixing segment342, and a fracking fluid outlet344. The base fluid inlet340is configured to be fluidly connected to the outlet126(FIG. 1) of the frac pump104(FIG. 1) for receiving the flow of base fluid from the frac pump104. The base fluid inlet340defines a higher-pressure entrance of the fluid delivery device314. For example, the base fluid inlet340defines a higher-pressure inlet of the fluid conduit336that receives the flow of base fluid from the higher-pressure side (i.e., the outlet126) of the frac pump104. The base fluid inlet340can be indirectly fluidly connected to the outlet126of the frac pump104via the missile108(FIG. 1) or can be directly fluidly connected to the outlet126of the frac pump104.

Each injection system338is configured to inject at least one material of the fracking fluid (e.g., from the blender112shown inFIG. 1, directly from one or more material sources110shown inFIG. 1, etc.) into the mixing segment342of the fluid conduit336to generate the fracking fluid within the mixing segment342. The fracking fluid outlet344is configured to be directly or indirectly fluidly connected to the well head102(FIG. 1) for delivering a flow of the fracking fluid to the well head102. The fracking fluid outlet344defines a higher-pressure outlet of the fluid conduit336. Accordingly, the fracking fluid outlet344defines a higher-pressure exit of the fluid delivery device314.

Referring now toFIGS. 3 and 4, each injection system338includes a syringe assembly339that includes a syringe346and a diverter374. The diverter374will be described in more detail below. The syringe346includes a material chamber348, a base fluid chamber350, a piston352, and an actuator354. The piston352includes a piston head356(not visible inFIG. 3) that extends within the base fluid chamber350and a piston ram358(not visible inFIG. 3) that extends within the material chamber348. The piston352is configured to move between an extended position and a retracted position such that the piston ram358extends and retracts within the material chamber348, as should be apparent fromFIG. 4. For example, the piston ram358of the injection system338is shown inFIG. 4in the retracted position. Operation of the piston252will be described in more detail below.

The actuator354is operatively connected to the piston352such that the actuator354is configured to move the piston352from the retracted position to the extended position. In the exemplary embodiment of the fluid delivery device314, the actuator354is a hydraulic actuator that is configured to move a rod362(not visible inFIG. 3) that is connected to the piston head356to thereby move the piston352from the retracted position to the extended position. In some examples, the actuator354is a hydraulic spool valve. The actuator354is not limited to being a hydraulic spool valve or any other type of hydraulic actuator (e.g., a hydraulic pump system, etc.), but rather additionally or alternatively can include any type of actuator that is capable of moving the piston352from the retracted position to the extended position, for example an electric motor, a linear actuator (e.g., a ball screw, a lead screw, a rotary screw, another screw-type actuator, a hydraulic linear actuator, a pneumatic linear actuator, a solenoid, a servo, another type of linear actuator, etc.), a pneumatic actuator, a servo, and/or the like.

The material chamber348of the syringe346of each injection system338includes a material inlet364that is fluidly connected to the outlet134(FIG. 1) of the blender112for receiving a flow of at least one material of the tracking fluid from the blender112. The material inlet364defines a lower-pressure entrance of the fluid delivery device314. For example, the material inlet364defines a lower-pressure inlet of the material chamber348. The material inlet364includes a material inlet valve366that controls the flow of material(s) from the blender112through the material inlet364into the material chamber348of the syringe346. Specifically, the material inlet valve366is moveable between an open position and a closed position. The open position of the material inlet valve366enables material(s) to flow from the blender112through the material inlet364into the material chamber348. The closed position of the material inlet valve366prevents material(s) from the blender112from flowing through the material inlet364into the material chamber348.

In the exemplary embodiment of the fluid delivery device314, the material inlet valve366is a check valve that is moved between the open and closed positions via pressure differentials across the valve366, as will be described below. In other examples, movement of the material inlet valve366between the open and closed positions is controlled by the control system of the hydraulic fracturing system100(e.g., based on a position of the piston ram358, based on a predetermined timing scheme, based on a particle count sensor (not shown) within the material chamber348, based on another sensor (not shown) within the material chamber348, etc.). In addition or alternatively to a check valve, the material inlet valve366can include any other type of valve (e.g., an integrated circuit (IC) driven valve, a programmable logic control (PLC) driven valve, another electrically controlled valve, etc.) that enables the hydraulic fracturing system100to function as described and/or illustrated herein.

Although described herein as being indirectly fluidly connected to the material source(s)110via the blender112, the material inlet364of the material chamber348of each syringe346can be directly fluidly connected to one or more of the material sources110for receiving a flow of at least one material of the fracking fluid directly therefrom. In the exemplary embodiment of the fluid delivery device314, the material inlets364are shown inFIG. 3as including a common entrance365for fluid connection with the blender112and/or the material source(s)110. But, in other examples one or more of the material inlets364can include a dedicated entrance for a separate fluid connection with the blender112and/or material source(s)110.

The material chamber348of the syringe346of each injection system338includes a material outlet368that is fluidly connected to the mixing segment342of the fluid conduit336. Accordingly, the material outlet368is fluidly connected to the fluid conduit336downstream from the base fluid inlet340and thus downstream from the frac pump104, as is shown herein. The material outlet368defines a higher-pressure outlet of the fluid conduit336. Accordingly, the material outlet368defines a higher-pressure exit of the fluid delivery device314.

The material outlet368includes a material outlet valve370that controls the flow of material(s) from the material chamber348of the syringe346through the material outlet368into the mixing segment342of the fluid conduit336. Specifically, the material outlet valve370is moveable between an open position and a closed position. The open position of the material outlet valve370enables material(s) to flow from the material chamber348through the material outlet368into the mixing segment342of the fluid conduit336. The closed position of the material outlet valve370prevents material(s) from the material chamber348from flowing through the material outlet368into the mixing segment342of the fluid conduit336.

In the exemplary embodiment of the fluid delivery device314, the material outlet valve370is a check valve that is moved between the open and closed positions via pressure differentials across the valve370. In other examples, movement of the material outlet valve370between the open and closed positions is controlled by the control system of the hydraulic fracturing system100(e.g., based on a position of the piston ram358, based on a predetermined timing scheme, based on a particle count sensor within the material chamber348, based on another sensor within the material chamber348, etc.). In addition or alternatively to a check valve, the material outlet valve370can include any other type of valve (e.g., an integrated circuit (IC) driven valve, a programmable logic control (PLC) driven valve, another electrically controlled valve, etc.) that enables the hydraulic fracturing system100to function as described and/or illustrated herein.

The base fluid chamber350of the syringe346of each injection system338includes a base fluid inlet372that is configured to be fluidly connected to the outlet126of the frac pump104for receiving a flow of base fluid from the frac pump104. The base fluid inlet372can be indirectly fluidly connected to the outlet126of the frac pump104via the missile108or can be directly fluidly connected to the outlet126of the frac pump104. The base fluid inlet372defines a higher-pressure entrance of the fluid delivery device214. For example, the base fluid inlet372defines a higher-pressure inlet of the base fluid chamber350. In the exemplary embodiment of the fluid delivery device314, the base fluid inlets372are shown inFIG. 3as including a common entrance375for fluid connection with outlet126of the frac pump104. But, in other examples one or more of the base fluid inlets372can include a dedicated entrance for a separate fluid connection with the outlet126of the frac pump104.

The base fluid chamber350of the syringe346of each injection system338includes a base fluid outlet376for discharging base fluid from the base fluid chamber350during retraction of the piston352. Optionally, the base fluid outlet376is fluidly connected to the inlet124(FIG. 1) of the frac pump104, the inlet128(FIG. 1) of the missile108, and/or one or more of the base fluid sources106for returning base fluid thereto from the base fluid chamber350. The frac pump104, the missile108, and the base fluid source(s)106may each be referred to herein as a “base fluid reservoir”. For example, the “base fluid reservoir” recited in the claims of the present disclosure may refer to the frac pump104, the missile108, and/or one or more base fluid sources106.

The base fluid outlet376defines a lower-pressure exit of the fluid delivery device314. For example, the base fluid outlet376defines a lower-pressure outlet of the base fluid chamber350. In the exemplary embodiment of the fluid delivery device314, the base fluid outlets376are shown inFIG. 3as including a common exit378for fluid connection with the inlet124of the frac pump104, the inlet128of the missile108, and/or the base fluid source(s)106. But, in other examples one or more of the base fluid outlets376can include a dedicated entrance for a separate fluid connection with the inlet124of the frac pump104, the inlet128of the missile108, and/or the base fluid source(s)106.

Referring now toFIG. 5, the diverter374will now be described. The diverter374is fluidly connected to the base fluid chamber350of the syringe346between the base fluid chamber350and the base fluid inlet372and between the base fluid chamber350and the base fluid outlet376. More particularly, the diverter374includes an interior chamber380that is fluidly connected to the base fluid chamber350. As can be seen inFIG. 5, the interior chamber380of the diverter374is fluidly connected to the base fluid inlet372and is fluidly connected to the base fluid outlet376.

Referring now toFIGS. 5-7, the diverter374controls the flow of base fluid into the base fluid chamber350(not shown inFIGS. 6 and 7) of the syringe346through the base fluid inlet372. The diverter374also controls the flow of base fluid out of the base fluid chamber350through the base fluid outlet376. More particularly, the diverter374is moveable between a first position382(shown inFIG. 6) and a second position384(shown inFIG. 7). In the first position382, the fluid connection of the interior chamber380to the base fluid outlet376is open and the fluid connection of the interior chamber380to the base fluid inlet372is closed. Accordingly, the first position382of the diverter374enables base fluid to flow out of the base fluid chamber350through the base fluid outlet376and prevents base fluid from flowing into the base fluid chamber350through the base fluid inlet372. In other words, the first position382of the diverter374fluidly connects base fluid chamber350to a base fluid reservoir (e.g., the inlet124(FIG. 1) of the frac pump104(FIG. 1), the inlet128(FIG. 1) of the missile108(FIG. 1), and/or one or more of the base fluid sources106(FIG. 1), etc.) of the hydraulic fracturing system100(FIG. 1) and fluidly disconnects the base fluid chamber350from the outlet126(FIG. 1) of the frac pump104. The first position382of the diverter374thus fluidly connects the base fluid chamber350to a lower pressure line of the hydraulic fracturing system100.

In the second position384of the diverter374, the fluid connection of the interior chamber380to the base fluid inlet372is open and the fluid connection of the interior chamber380to the base fluid outlet376is closed. Accordingly, the second position384of the diverter374enables base fluid to flow into the base fluid chamber350through the base fluid inlet372and prevents base fluid from flowing out of the base fluid chamber350through the base fluid outlet376. In other words, the second position384of the diverter374fluidly connects base fluid chamber350to the outlet126of the frac pump104and fluidly disconnects the base fluid chamber350from the base fluid reservoir of the hydraulic fracturing system100. The second position384of the diverter374thus fluidly connects the base fluid chamber350to a higher pressure line of the hydraulic fracturing system100.

Referring now solely toFIGS. 6 and 7, the diverter374can have any structure that enables the diverter374to function as described and/or illustrated herein. In the exemplary embodiment, the diverter374includes an actuator386, a spool rod388, a base fluid inlet valve390, and a base fluid outlet valve392. As can be seen inFIGS. 6 and 7, the spool rod388is held within the interior chamber380of the diverter374and the base fluid inlet and outlet valves390and392, respectively, are held on the spool rod388. The spool rod388reciprocates within the interior chamber380between the first position382shown inFIG. 6and the second position384shown inFIG. 7to thereby open and close the valves390and392. In the first position382of the diverter374shown inFIG. 6, the base fluid inlet valve390is engaged with an inlet valve seat394of the diverter374such that the base fluid inlet valve390is closed, while the base fluid outlet valve392is separated from an outlet valve seat396of the diverter374such that the base fluid outlet valve392is open. In the second position384of the diverter374shown inFIG. 7, the base fluid inlet valve390is separated from the inlet valve seat394such that the base fluid inlet valve390is open, while the base fluid outlet valve392is engaged with the outlet valve seat396such that the base fluid outlet valve392is closed. The base fluid outlet valve392may be referred to herein (e.g., in the claims of the present disclosure) as a “first valve”, while the base fluid inlet valve390may be referred to herein as a “second valve”.

The actuator386is operatively connected to the spool rod388such that the actuator386is configured to reciprocate the spool rod388between the first and second positions382and384, respectively, of the diverter374. More particularly, the actuator386is configured to move the spool rod388in the direction of the arrow398to position the valves390and392of the diverter374into the first position382of the diverter374; and the actuator386is configured to move the spool rod388in the direction of the arrow400to position the valves390and392of the diverter374into the second position384of the diverter374. In the exemplary embodiment, the actuator386includes a rod402that is connected to the spool rod388such that movement of the rod402in the directions of the arrows398and400reciprocates the spool rod388within the interior chamber380. But, the actuator386additionally or alternatively can include any other arrangement, configuration, structure, and/or the like that enables the actuator386to reciprocate the spool rod388within the interior chamber380of the diverter374.

In the exemplary embodiment, the actuator386is a hydraulic actuator. In some examples, the actuator386is a hydraulic spool valve. But, the actuator386additionally or alternatively can include any other type of hydraulic actuator (e.g., a hydraulic pump system, a hydraulic linear actuator, etc.). Moreover, the actuator386is not limited to being a hydraulic actuator. Rather, additionally or alternatively the actuator386can include any type of actuator that is capable of moving the spool rod388of the diverter374between the first and second positions382and384, respectively. For example, the actuator386can include an electric motor, a linear actuator (e.g., a ball screw, a lead screw, a rotary screw, another screw-type actuator, a pneumatic linear actuator, a solenoid, a servo, another type of linear actuator, etc.), a pneumatic actuator, a servo, and/or the like.

Movement of the diverter374between the first position382and the second position384can be controlled by the control system of the hydraulic fracturing system100. In some examples, movement of the diverter374between the first position382and the second position384is based on a position of the piston head356. In other examples, movement of the diverter374between the first position382and the second position384is based on a predetermined timing scheme, a particle count sensor within the material chamber348, another sensor within the material chamber348, and/or the like. In some examples, movement of the diverter374between the first position382and the second position384is electronically controlled (e.g., using an integrated circuit (IC), a programmable logic control (PLC), another electrical control, etc.).

In addition or alternatively to the specific arrangement, configuration, structure, and/or the like shown and/or described herein (e.g., the actuator386, the spool rod388, the rod402, the valve390, the valve392, the seat394, the seat396, the interior chamber380, etc.), the diverter374can have any other arrangement, configuration, structure, and/or the like that enables the diverter374to function as described and/or illustrated herein.

Referring now toFIGS. 1-7, operation of the syringe346of the injection system338awill now be described to provide a general understanding of the operation of the fluid delivery device314. The operation of the syringes346of each of the injections systems338is substantially similar such that the operational description of the injection system338ashould be understood as being representative of the operation of the injection systems338band338b.

At the beginning of a cycle, the diverter374is moved to the first position382shown inFIG. 6to fluidly connect the base fluid chamber350of the syringe346with the lower pressure line of a base fluid reservoir (e.g., the inlet124(FIG. 1) of the frac pump104(FIG. 1), the inlet128(FIG. 1) of the missile108(FIG. 1), and/or one or more of the base fluid sources106(FIG. 1), etc.) of the hydraulic fracturing system100. Movement of the diverter374to the first position382also fluidly disconnects the base fluid chamber350from the outlet126of the frac pump100. The lower-pressure within the base fluid chamber350retracts the piston352of the syringe346, thereby creating a lower-pressure suction within the material chamber348of the syringe346that opens the material inlet valve366and draws one or more materials of the tracking fluid from the blender112into the material chamber348through the material inlet364. The fluid connection of the base fluid chamber350to the lower pressure line of the base fluid reservoir, as well as the retraction of the piston352, discharges (i.e., releases) base fluid from the base fluid chamber350through the base fluid outlet376. In the exemplary embodiment, the suction within the material chamber348and/or a bias of the material outlet valve370to the closed position closes (or maintains as closed) the material outlet valve370during retraction of the piston352.

Once the piston352reaches a fully retracted position, the diverter374is moved to the second position384shown inFIG. 7to fluidly connect the base fluid chamber350with the higher pressure line of the outlet126of the frac pump104and fluidly disconnect that base fluid chamber350from the base fluid reservoir. The fluid connection between the base fluid chamber350and the outlet126of the frac pump104enables base fluid from the outlet126of the frac pump104to flow into the base fluid chamber350and thereby increase the pressure within the base fluid chamber350such that the pressure within the base fluid chamber350is approximately equalized with the pressure within the material chamber348of the syringe346. Once the pressure within the chambers348and350is approximately equal via the movement of the diverter374to the second position, the actuator354is actuated to extend the piston352(i.e., move the piston352from the retracted position to the extended position). In other words, the actuator354extends the piston352while (i.e., when) the diverter374is in the second position384. As the piston352moves to the extended position, the piston ram358pressurizes the material(s) from the blender112contained within the material chamber348such that the material outlet valve opens370opens and the material(s) contained within the material chamber348discharge (i.e., are injected) into the mixing segment342of the fluid conduit336through the material outlet368. The syringe346thereby generates the fracking fluid within the mixing segment342for delivery to the well head102through the fracking fluid outlet344. Accordingly, the syringe346injects the material(s) into the fluid conduit336downstream from the frac pump104. In the exemplary embodiment, the pressure within the material chamber348and/or a bias of the material inlet valve366to the closed position closes the material outlet inlet valve366at the onset of extension of the piston352.

Once the material(s) drawn into the material chamber348from the blender112have been discharged into the mixing segment342of the fluid conduit336, the diverter374is moved from the second position384back to the first position382to repeat the cycle of the syringe346drawing the material(s) from the blender112into the material chamber348and injecting the material(s) into the mixing segment342to generate the fracking fluid within the fluid conduit336.

In some examples, the material(s) injected into the mixing segment342from the material chamber348mix with base fluid flowing through the mixing segment342to form (i.e., generate) the fracking fluid within the mixing segment342. In other examples, the material(s) injected into the mixing segment342from the material chamber348define a finished (i.e., complete) fracking fluid that is ready for delivery to the well head102. Although the fluid delivery device314is described herein as delivering a fracking fluid to the well head102, in other examples the fluid delivery device314can be used to transport, divert, convey, or otherwise move one or more solid materials (e.g., sand, sandstone, ceramic beads, sintered bauxite, aluminum, other oil and gas well stimulation proppant, etc.) to the well head102.

Using two or more injection systems338(and/or two or more fluid delivery devices314) can enable the fluid delivery device(s)314to deliver a substantially continuous flow of fracking fluid to the well head102during operation of the hydraulic fracturing system100. More particularly, the syringes346of the injection systems338(and/or two or more fluid delivery devices314) can be cycled between injection phases in an offset timing pattern. The ability of the fluid delivery device(s)314to deliver a substantially continuous supply of the fracking fluid to the well head102mitigates the potential for base fluid that has not been mixed with any other materials of the fracking fluid to flow into the well head102.

The hydraulic fracturing system100can include any number of the fluid delivery devices314(each of which can include any number of the injection systems338) to facilitate delivering a substantially continuous flow of fracking fluid to the well head102. Non-limiting examples include a fluid delivery device314having two, three, four, five, ten, or twenty injection systems338timed to deliver a substantially continuous flow of fracking fluid to the well head102. Other non-limiting examples include two, three, four, five, ten, or twenty fluid delivery devices314(each of which can include any number of the injection systems338) timed to deliver a substantially continuous flow of fracking fluid to the well head102.

Referring now toFIG. 8, a method500for operating a hydraulic fracturing system according to an exemplary embodiment is shown. At step502, the method500includes pumping a base fluid from the outlet of a frac pump into a fluid conduit. The method500includes injecting, at504, at least one material of a fracking fluid into the fluid conduit downstream from the frac pump to generate the fracking fluid within the fluid conduit. At step506, the method500includes pumping the fracking fluid from the fluid conduit into a well head.

The steps of the method500can be performed in any order. For example, injecting at504the at least one material of the fracking fluid into the fluid conduit can be performed before any base fluid is pumped at502into the fluid conduit, wherein the step of pumping at506the fracking fluid from the fluid conduit into the well head can include pumping at502the base fluid from the outlet of the frac pump into the fluid conduit.

Referring now toFIG. 9, a method600for operating a syringe of a hydraulic fracturing system according to an exemplary embodiment is shown. At step602, the method600includes fluidly connecting a base fluid chamber of the syringe with a base fluid reservoir to thereby draw at least one material of a fracking fluid into a material chamber of the syringe. The method step602includes fluidly connecting, at602a, the base fluid chamber to a lower pressure line. The method step602includes moving, at602b, a diverter to a first position wherein a first valve of the diverter is open and a second valve of the diverter is closed. At602c, the method step602includes retracting a piston of the syringe. The method step602includes fluidly disconnecting, at602d, the base fluid chamber of the syringe from the outlet of the frac pump.

At step604, the method600includes fluidly connecting the base fluid chamber of the syringe with an outlet of a frac pump of the hydraulic fracturing system to approximately equalize the pressure within the base fluid chamber and the material chamber. The method step604includes fluidly connecting, at604a, the base fluid chamber to a higher pressure line. At step604b, the method step604includes moving the diverter to a second position wherein the second valve is open and the first valve is closed. At step604c, the method step604includes fluidly disconnecting the base fluid chamber of the syringe from the base fluid reservoir.

The method600includes actuating, at606, the syringe to inject the at least one material from the material chamber into a fluid conduit when the base fluid chamber of the syringe is fluidly connected to the outlet of the frac pump. At step606a, the method step606includes extending the piston of the syringe using an actuator of the syringe. At step606b, the method step606includes injecting the at least one material into the fluid conduit downstream from the frac pump.

The syringe assemblies, fluid delivery devices, and operational methods described and/or illustrated herein can mitigate the amount of relatively abrasive material that flows through the fluid end of a frac pump by introducing relatively abrasive material into a hydraulic fracturing system after the fluid end of a frac pump (i.e., downstream from the outlet of the frac pump). In some examples, the fluid end of a frac pump will pump a relatively non-abrasive base fluid (e.g., water) exclusively. The syringe assemblies, fluid delivery devices, and operational methods described and/or illustrated herein reduce wear and erosion on the interior surfaces (e.g., the various internal passages, etc.) and/or the internal components (e.g., valves, seats, springs, etc.) of the fluid end of a frac pump. The syringe assemblies, fluid delivery devices, and operational methods described and/or illustrated herein increase (i.e., extend) the longevity and thus the operational life of the fluid ends of frac pumps.

The syringe assemblies, fluid delivery devices, and operational methods described and/or illustrated herein that introduce relatively abrasive materials of a fracking fluid after the fluid end of a frac pump can provide numerous benefits over conventional systems used for hydraulic fracturing, for example the following benefits, without limitation: a fluid end of a frac pump that wears significantly less due to the lack of relatively abrasive material flowing through the fluid end; internal surfaces and/or components of a fluid end that wear significantly less due to the lack of relatively abrasive material flowing through the fluid end; gates of a hydraulic fracturing system will take on significant wear instead of the fluid end of a frac pump; and the fluid end of a frac pump will resist failure for a longer period of time.

The following clauses describe further aspects of the disclosure:

Clause Set A:

A1. A syringe assembly for a hydraulic fracturing system, said syringe assembly comprising:

a syringe having a material chamber, a base fluid chamber, and a piston, the material chamber being configured to be fluidly connected to a fluid conduit of the hydraulic fracturing system, the piston being configured to retract to draw at least one material into the material chamber, the piston being configured to extend to push the at least one material into the fluid conduit; and

a diverter fluidly connected to the base fluid chamber and moveable between first and second positions, wherein the first position of the diverter is configured to fluidly connect the base fluid chamber to a base fluid reservoir of the hydraulic fracturing system and fluidly disconnect the base fluid chamber from an outlet of a frac pump of the hydraulic fracturing system, and wherein the second position of the diverter is configured to fluidly connect the base fluid chamber to the outlet of the frac pump and fluidly disconnect the base fluid chamber from the base fluid reservoir.

A2. The syringe assembly of clause A1, wherein the second position of the diverter is configured to approximately equalize the pressure of the base fluid chamber and the material chamber of the syringe.

A3. The syringe assembly of clause A1, wherein the second position of the diverter is configured to increase the pressure of fluid contained within the base fluid chamber of the syringe, the first position of the diverter being configured to release fluid from the base fluid chamber.

A4. The syringe assembly of clause A1, wherein the diverter comprises first and second valves, the first valve being open and the second valve being closed in the first position of the diverter, the first valve being closed and the second valve being open in the second position of the diverter.

A5. The syringe assembly of clause A1, wherein the diverter comprises a rod and first and second valves held on the rod, the rod reciprocating between the first and second positions of the diverter to open and close the first and second valves.

A6. The syringe assembly of clause A1, wherein the diverter comprises a hydraulic actuator configured to move the diverter between the first and second positions.

A7. The syringe assembly of clause A1, wherein the diverter comprises a spool valve configured to move the diverter between the first and second positions.

A8. The syringe assembly of clause A1, wherein the syringe comprises an actuator configured to extend the piston.

A9. The syringe assembly of clause A1, wherein the syringe comprises an actuator configured to extend the piston when the diverter is in the second position.

Clause Set B:

B1. A fluid delivery device for a hydraulic fracturing system, said fluid delivery device comprising:

a fluid conduit comprising a fracking fluid outlet configured to be fluidly connected to a well head for delivering a fracking fluid to the well head, the fluid conduit comprising a base fluid inlet configured to be fluidly connected to an outlet of a frac pump of the hydraulic fracturing system;

a syringe having a material chamber fluidly connected to the fluid conduit downstream from the frac pump, the material chamber being configured to be fluidly connected to a material source, the syringe comprising a base fluid chamber, the syringe comprising a piston that is configured to retract to draw at least one material of the fracking fluid into the material chamber from the material source, the piston being configured to extend to push the at least one material of the fracking fluid from the material chamber into the fluid conduit; and

a diverter fluidly connected to the base fluid chamber and moveable between first and second positions, wherein the first position of the diverter is configured to fluidly connect the base fluid chamber to a base fluid reservoir of the hydraulic fracturing system and fluidly disconnect the base fluid chamber from the outlet of the frac pump, and wherein the second position of the diverter is configured to fluidly connect the base fluid chamber to the outlet of the frac pump and fluidly disconnect the base fluid chamber from the base fluid reservoir.

B2. The fluid delivery device of clause B1, wherein the second position of the diverter is configured to approximately equalize the pressure of the base fluid chamber and the material chamber of the syringe.

B3. The fluid delivery device of clause B1, wherein the diverter comprises a rod and first and second valves held on the rod, the rod reciprocating between the first and second positions of the diverter to open and close the first and second valves.

B4. The fluid delivery device of clause B1, wherein the diverter comprises a hydraulic actuator configured to move the diverter between the first and second positions.

B5. The fluid delivery device of clause B1, wherein the syringe comprises an actuator configured to extend the piston.

Clause Set C:

C1. A method for operating a syringe of a hydraulic fracturing system, said method comprising:

fluidly connecting a base fluid chamber of the syringe with a base fluid reservoir to thereby draw at least one material of a fracking fluid into a material chamber of the syringe;

fluidly connecting the base fluid chamber of the syringe with an outlet of a frac pump of the hydraulic fracturing system to approximately equalize the pressure within the base fluid chamber and the material chamber; and

actuating the syringe to inject the at least one material from the material chamber into a fluid conduit when the base fluid chamber of the syringe is fluidly connected to the outlet of the frac pump.

C2. The method of clause C1, wherein fluidly connecting the base fluid chamber of the syringe with the base fluid reservoir comprises fluidly connecting the base fluid chamber to a lower pressure line, and wherein fluidly connecting the base fluid chamber of the syringe with the outlet of the frac pump comprises fluidly connecting the base fluid chamber to a higher pressure line.

C3. The method of clause C1, wherein fluidly connecting the base fluid chamber of the syringe with the base fluid reservoir comprises moving a diverter to a first position wherein a first valve of the diverter is open and a second valve of the diverter is closed, and wherein fluidly connecting the base fluid chamber of the syringe with the outlet of the frac pump comprises moving the diverter to a second position wherein the second valve is open and the first valve is closed.

C4. The method of clause C1, wherein fluidly connecting the base fluid chamber of the syringe with the base fluid reservoir comprises retracting a piston of the syringe, and wherein actuating the syringe to inject the at least one material from the material chamber into the fluid conduit when the base fluid chamber is fluidly connected to the outlet of the frac pump comprises extending the piston using an actuator of the syringe.

C5. The method of clause C1, wherein fluidly connecting the base fluid chamber of the syringe with the base fluid reservoir comprises fluidly disconnecting the base fluid chamber of the syringe from the outlet of the frac pump, and wherein fluidly connecting the base fluid chamber of the syringe with the outlet of the frac pump comprises fluidly disconnecting the base fluid chamber of the syringe from the base fluid reservoir.

C6. The method of clause C1, wherein actuating the syringe to inject the at least one material from the material chamber into the fluid conduit when the base fluid chamber is fluidly connected to the outlet of the frac pump comprises injecting the at least one material into the fluid conduit downstream from the frac pump.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) can be used in combination with each other. Furthermore, invention(s) have been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Further, each independent feature or component of any given assembly can constitute an additional embodiment. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the disclosure without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “clockwise” and “counterclockwise”, “left” and right”, “front” and “rear”, “above” and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

When introducing elements of aspects of the disclosure or the examples thereof, 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 can be additional elements other than the listed elements. For example, in this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised”, “comprises”, “having”, “has”, “includes”, and “including” where they appear. The term “exemplary” is intended to mean “an example of” The phrase “one or more of the following: A, B, and C” means “at least one of A and/or at least one of B and/or at least one of C.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.

Although the terms “step” and/or “block” may be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described. The order of execution or performance of the operations in examples of the disclosure illustrated and described herein is not essential, unless otherwise specified. The operations can be performed in any order, unless otherwise specified, and examples of the disclosure can include additional or fewer operations than those disclosed herein. It is therefore contemplated that executing or performing a particular operation before, contemporaneously with, or after another operation is within the scope of aspects of the disclosure.