Patent Publication Number: US-2023160289-A1

Title: High and Low Pressure Manifold Liquid Supply System for Fracturing Units

Description:
CROSS REFERENCE 
     The present application is a continuation application of and claims the benefit of priority to U.S. patent application Ser. No. 17/205,388 filed on Mar. 18, 2021 and titled “HIGH AND LOW PRESSURE MANIFOLD LIQUID SUPPLY SYSTEM FOR FRACTURING UNITS,” the entirety of which is herein incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to the technical field of oil and gas field fracturing, more specifically, to a high and lower pressure manifold liquid supply system for fracturing units 
     BACKGROUND 
     In a fracturing operation site of oil and gas field, a power supply and transmission system of a traditional fracturing unit typically includes: a diesel engine as a power source, a fracturing plunger pump as an actuator, and a gearbox as well as a transmission shaft connected therebetween for transmitting power. However, the diesel engine as the power source has disadvantages of, for example, low power, large volume, high fuel costs, as well as waste gas pollution and noise pollution. Apart from this, the well site layout using the diesel engine as the power source occupies a large area. Therefore, the use of electric motors instead of diesel engines as well as transmissions thereof for directly driving fracturing units has gradually become a new trend in development which has gradually been spotted in practical applications. When electrically-driven fracturing units are employed, there arise new problems, such as complicated connection of the electricity distribution system at the well site, a long connection distance, a time-consuming connection process, and the like. In addition, since electrical interfaces of the electrically-driven fracturing units are arranged at the head portions of the electrically-driven fracturing trailers for carrying the electrically-driven fracturing units while the fracturing fluid connection interfaces of the electrically-driven fracturing units are arranged at the rear portions of the electrically-driven fracturing trailers, therefore causing hindrances for moving the electrically-driven fracturing trailers. 
       FIG.  1    illustrates a diagram of a well site layout according to the prior art, where a power supply system  1  is typically located at a position distant away from electrically-driven fracturing trailers and electrically connected to electrical interfaces in a vicinity of head portions (i.e., the left side in  FIG.  1   ) of the electrically-driven fracturing trailers via multiple long cables to supply electricity to electrically-driven fracturing units  2 , low pressure fracturing fluid provided by electrically-driven sand mixing units  3  on electrically-driven sand mixing trailers are delivered via a high and low pressure manifold  4  to fluid interfaces in a vicinity of rear portions (i.e., the right side in  FIG.  1   ) of the electrically-driven fracturing trailers, and the electrically-driven fracturing units  2  pressurize low pressure fracturing fluid into high pressure fracturing fluid and deliver high pressure fracturing fluid back to the high and low pressure manifold  4  and further to a wellhead  5  via the high and low pressure manifold  4 . Given the fact that each electrically-driven fracturing unit  2  needs to be separately electrically connected to the power supply system  1 , a large number of cables are required in such arrangement. Moreover, for the electrically-driven fracturing units  2 , connection interfaces are provided in the vicinity of both the head and rear portions of the trailers, thus resulting in complicated connection and causing hindrances for moving the electrically-driven fracturing trailers. 
     As a result, there is a need for improving the electricity supply and distribution system of the well site to at least partly solve the foregoing problems. 
     SUMMARY 
     The objective of the present disclosure is to provide a high and low pressure manifold liquid supply system for fracturing units, which can simplify the electricity distribution layout, save the well site space, and facilitate operations. 
     According to an aspect of the present disclosure, the high and lower pressure manifold liquid supply system comprises: 
     a trailer comprising a platform; 
     a high and low pressure manifold arranged on the platform and configured to deliver low pressure fracturing fluid from one or more sand mixing units to a plurality of electrically-driven fracturing units and to receive high pressure fracturing fluid from the plurality of electrically-driven fracturing units; 
     a support frame arranged on the platform; and 
     a distribution switch cabinet fixed on the support frame and configured to distribute electricity to the plurality of electrically-driven fracturing units. 
     According to the present disclosure, the generator set is only required to be connected to the distribution switch cabinet of the high and low pressure manifold liquid supply system, without the necessity of separately connecting to each electrically-driven fracturing unit. In this way, the amount of cables required for connecting the electrically-driven fracturing units can be significantly reduced, thus simplifying the connection complexity of the electrically-driven fracturing units. 
     In an embodiment, the high and low pressure manifold comprises: 
     a low pressure manifold comprising one or more low pressure inlets in fluid communication with the one or more sand mixing units to receive the low pressure fracturing fluid from the one or more sand mixing units, and a plurality of low pressure outlets in fluid communication with the plurality of electrically-driven fracturing units to deliver the low pressure fracturing fluid to the plurality of electrically-driven fracturing units; 
     a high pressure manifold comprising a plurality of high pressure inlets in fluid communication with the plurality of electrically-driven fracturing units to receive the high pressure fracturing fluid from the plurality of electrically-driven fracturing units, and one or more high pressure outlets in fluid communication with a wellhead to deliver the high pressure fracturing fluid to the wellhead. 
     According to the present disclosure, the high and low pressure manifold liquid supply system can simultaneously perform the functions of delivering fracturing fluid and supplying electricity. 
     In an embodiment, the plurality of low pressure outlets are arranged at both lateral sides of the high and low pressure manifold, and the plurality of high pressure inlets are arranged at both lateral sides of the high and low pressure manifold. 
     According to the present disclosure, the high and low pressure manifold at both lateral sides can be connected to the electrically-driven fracturing units, thereby increasing the number of the electrically-driven fracturing units and improving the operation efficiency. 
     In an embodiment, the distribution switch cabinet comprises: 
     a power input interface configured to be electrically connected to a generator set to receive power supplied by the generator set; 
     a plurality of electrical junction boxes configured to be electrically connected to the plurality of electrically-driven fracturing units, respectively, to deliver the power to the plurality of electrically-driven fracturing units; and 
     a plurality of distribution switches configured to distribute electricity to the plurality of electrically-driven fracturing units. 
     According to the present disclosure, the high and low pressure manifold can perform an electricity distribution function for the plurality of electrically-driven fracturing units when delivering fracturing fluid. 
     In an embodiment, the high and low pressure manifold liquid supply system further comprises: 
     a plurality of prefabricated low flow-pressure cables and a plurality of prefabricated high flow-pressure cables, for electrically connecting the distribution switch cabinet with the plurality of electrically-driven fracturing units. 
     According to the present disclosure, the plurality of electrically-driven fracturing units can be directly electrically connected to the high and low pressure manifold, without the necessity of connecting to the generator set distant away, thereby reducing the number of connection cables. 
     In an embodiment, the low flow-pressure cables are arranged adjacent to a low pressure fluid pipeline connected between the plurality of low pressure outlets and the electrically-driven fracturing units and fixed on the low pressure fluid pipeline, and the high flow-pressure cables are arranged adjacent to a high pressure fluid pipeline connected between the plurality of high pressure inlets and the electrically-driven fracturing units and fixed on the high pressure fluid pipeline. 
     According to the present disclosure, the cables are arranged adjacent to the fluid pipelines connected between the electrically-driven fracturing units and the high and low pressure manifold, to render the high and low pressure manifold liquid supply system more compact. 
     In an embodiment, the sand mixing units are electrically-driven sand mixing units, and the distribution switch cabinet is further configured to distribute electricity to the sand mixing units. 
     According to the present disclosure, the sand mixing units can be directly electrically connected to the high and low pressure manifold, without the necessity of connecting to the generator set distant away, thereby reducing the number of connection cables. 
     In an embodiment, the electrical junction boxes are further electrically connected to the sand mixing units, and the distribution switches are further configured to distribute electricity to the sand mixing units. 
     According to the present disclosure, the high and low pressure manifold can perform an electricity distribution function for the sand mixing units when delivering fracturing fluid. 
     In an embodiment, the electrically-driven fracturing units are arranged on electrically-driven fracturing trailers, and the low pressure manifold and the high pressure manifold are in fluid communication with fluid inlets and outlets of the electrically-driven fracturing units located in a vicinity of rear portions of the electrically-driven fracturing trailers via the low pressure fluid pipeline and the high pressure fluid pipeline respectively. 
     In the embodiment, the low flow-pressure cables and the high flow-pressure cables are electrically connected to electrical interfaces of the electrically-driven fracturing units located in the vicinity of the rear portions of the electrically-driven fracturing trailers, respectively. 
     According to the present disclosure, the electrical interfaces of the electrically-driven fracturing units and the fluid inlets and outlets are all located in the vicinity of rear portions of the electrically-driven fracturing trailers, thereby simplifying the connection process, without causing hindrances for moving the electrically-driven trailers. 
     In an embodiment, the generator set is a gas turbine generator set, and a fuel consumed by the gas turbine generator set may be a compressed natural gas (CNG) or a liquefied natural gas (LNG). 
     According to the present disclosure, the electrically-driven fracturing operation in a well site can be more environment-friendly and more efficient. 
     In an embodiment, the generator set is a gas turbine generator set, and a fuel consumed by the gas turbine generator set is a wellhead gas. 
     According to the present disclosure, the well site generator set may directly take use of wellhead gas, thereby reducing costs. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order to better understand the above and other objectives, features and advantages of the present disclosure, preferred embodiments as shown in the accompanied drawings are provided. Throughout the drawings, the same or similar reference signs refer to the same or similar elements. It would be appreciated by those skilled in the art that the drawings are provided to illustrate the preferred embodiments of the present disclosure, without suggesting any limitation to the scope of the present disclosure, and respective components therein are not drawn to scale. 
         FIG.  1    illustrates a diagram of a well site layout according to the prior art. 
         FIG.  2    schematically illustrates a high and low pressure manifold liquid supply system according to the present disclosure. 
         FIG.  3    schematically illustrates a well site layout where a high and low pressure manifold liquid supply system according to the present disclosure is employed. 
     
    
    
     REFERENCE SIGNS 
     
         
           1  generator set 
           2  electrically-driven fracturing unit 
           3  electrically-driven sand mixing unit 
           4  high and low pressure manifold 
           5  wellhead 
           10  generator set 
           20  electrically-driven fracturing unit 
           30  sand mixing unit 
           40  high and low pressure manifold liquid supply system 
           41  trailer 
           42  high and low pressure manifold 
           421  low pressure manifold 
           4211  low pressure inlet 
           4212  low pressure outlet 
           422  high pressure manifold 
           4221  high pressure inlet 
           4222  high pressure outlet 
           423  low pressure fluid pipeline 
           424  high pressure fluid pipeline 
           43  support frame 
           44  distribution switch cabinet 
           441  electrical junction box 
           50  wellhead 
       
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Reference will now be made to the drawings to describe in detail the embodiments of the present disclosure. The description here is only about preferred embodiments of the present disclosure, and those skilled in the art would envision, on the basis of the preferred embodiments described herein, other manners that can implement the present disclosure, which also fall into the scope of the present disclosure. 
     The present disclosure provides a high and low pressure manifold liquid supply system for fracturing units, which is integrated with power supply facilities. Hereinafter, the high and low pressure manifold liquid supply system according to the present disclosure will be described in detail with reference to the accompanied drawings. The term “liquid” may be alternatively referred to as “fluid”. 
     As shown in  FIGS.  2  and  3   , the high and low pressure manifold liquid supply system  40  according to the present disclosure includes a trailer  41  having a platform, a high and low pressure manifold  42  arranged on the platform, a support frame  43  arranged on the platform, and distribution switch cabinet  44  arranged on the support frame  43 . The upstream of the high and low pressure manifold  42  is in fluid communication with one or more sand mixing units  30  (only one is shown in  FIG.  3   ) to receive low pressure fracturing fluid therefrom, and the downstream of the high and low pressure manifold  42  is in fluid communication with a plurality of electrically-driven fracturing units  20  to deliver the low pressure fracturing fluid to the fracturing units  20 . The electrically-driven fracturing units  20  pressurize the low pressure fracturing fluid into high pressure fracturing fluid and then deliver them back to the high and low pressure manifold  42  and further to the wellhead of the oil gas field via the high and low pressure manifold  42 , for fracturing operations. In addition, the high and low pressure manifold fluid supply system  40  according to the present disclosure further includes a distribution switch cabinet  44  fixed on the support frame  43  for distributing electricity to the electrically-driven fracturing units  20 . 
     According to a preferred embodiment of the present disclosure, the high and low pressure manifold  42  includes a low pressure manifold  421  for delivering low pressure fracturing fluid and a high pressure manifold  422  for delivering high pressure fracturing fluid. The low pressure manifold  421  is in fluid communication with one or more sand mixing units  30  to receive the low pressure fracturing fluid from the latter, and the low pressure manifold  421  is further in fluid communication with the plurality of electrically-driven fracturing units  20  to deliver the low pressure fracturing fluid to the latter for pressurization. The high pressure manifold  422  is in fluid communication with the plurality of electrically-driven fracturing units  20  to receive high pressure fracturing fluid pressurized by the plurality of electrically-driven fracturing units  20 , and collects the high pressure fracturing fluid and delivers them to the wellhead  50  (see  FIG.  3   ). 
     The low pressure manifold  421  includes one or more low pressure inlets  4211  and a plurality of low pressure outlets  4212 , for delivering the low pressure fracturing fluid from the sand mixing units  30  via the low pressure inlets  4211  to the low pressure manifold  421 , and then delivering the same via the low pressure outlets  4212  to the electrically-driven fracturing units  20  for pressurization. 
     The high pressure manifold  422  includes a plurality of high pressure inlets  4221  and one or more high pressure outlets  4222 , for delivering the high pressure fracturing fluid pressurized by the electrically driven fracturing units  20  via the high pressure inlets  4221  to the high pressure manifold  422 , and then delivering the same via the high pressure outlets  4222  to the wellhead  50 . 
     In a preferred embodiment, the low pressure outlets  4212  of the low pressure manifold and the high pressure inlets  4221  of the high pressure manifold are arranged at both lateral sides of the high and low pressure manifold  42  such that the electrically-driven fracturing units  20  can be connected to the high and low pressure manifold  42  at both lateral sides of the high and low pressure manifold  42 . 
     Further, the low pressure inlets  4211  and the high pressure outlets  4222  are preferably provided at longitudinal ends of the high and low pressure manifold  42  respectively. 
     According to a preferred embodiment of the present disclosure, the distribution switch cabinet  44  includes a power input interface and a plurality of electrical junction boxes  441 , where the power input interface is configured to be electrically connected to the generator set  10  for receiving electricity, and the electrical junction boxes  441  are configured to be electrically connected to the respective electrically-driven fracturing units  20 . In addition, the distribution switch cabinet  44  further includes a plurality of distribution switches for performing an electricity distribution operation for the electrically-driven fracturing units  20 . 
     In a preferred embodiment, the high and pressure manifold liquid supply system  40  includes a plurality of prefabricated low flow-pressure cables and a plurality of prefabricated high flow-pressure cables (not shown in figures) to form a current loop between the distribution switch cabinet  44  and the electrically driven fracturing units  20  for delivering the electricity from the distribution switch cabinet  44  to the electrically-driven fracturing units  20 . The low flow-pressure cables may refer to electric cables that are used or configured to carry electric power from a lower-voltage electric source (e.g., a 480-volt source), whereas the high flow-pressure cables refer to electric cables that may be used/configured to carry electric power from a higher-voltage electric source (e.g., a voltage that is higher than 480 volts). The low flow-pressure cables and the high flow-pressure cables may be manufactured using different processes resulting in electric cables that can withstand different lower and higher ranges of voltage, respectively. The high flow-pressure cables, for example, may have a different insulating shell/cladding composition and manufacturing process with a higher insulation bread-down voltage. The low flow-pressure cables and high flow-pressure cables, for example may be of a first power grade and a second power grade. The first power grade may be lower than the second power grade. For example, the high flow-pressure cables may be thicker than the low flow-pressure cables in either conductor diameters, insulator walls, or both. In some implementations, the low flow-pressure cables are arranged adjacent to a low pressure fluid pipeline  423  connected between the low pressure outlets  4212  and the electrically-driven fracturing units  20  for delivering the low pressure fracturing fluid to the electrically-driven fracturing units  20 , and preferably fixed on the low pressure fluid pipeline  423 . The high flow-pressure cables are arranged adjacent to the high pressure fluid pipeline  424  connected between the high pressure inlets  4221  and the electrically-driven fracturing units  20  for delivering the high pressure fracturing fluid to the high pressure manifold  422 , and preferably fixed on the high pressure fluid pipeline  424 . By prefabricating the high and low flow-pressure electricity supply cables, the connection distance between the units can be reduced, the time spent on connection can be saved, and the well site layout arranging efficiency can be improved. Moreover, the arrangement and movement of the units are free of the influence of the connection cables thus enabling easy detachment from the well site. 
     In a preferred embodiment, the sand mixing units are electrically-driven sand mixing units, and the distribution switch cabinet  44  can distribute electricity to the sand mixing units  30 . In the embodiment, the electrical junction boxes  441  are electrically connected to the sand mixing units  30  via cables which, for example, may be arranged adjacent to the fluid pipeline connected between the electrically-driven sand mixing units  30  and the high and low pressure manifold  42  and fixed thereto. Meanwhile, the distribution switches can perform an electricity distribution operation on the sand mixing units  30 . 
     According to a preferred embodiment of the present disclosure, the electrically-driven fracturing units  20  are arranged on the electrically-driven fracturing trailers, and the low pressure manifold  421  and the high pressure manifold  422  are respectively in fluid communication with the fluid inlets and outlets of the electrically-driven units  20  via the low pressure fluid pipeline  423  and the high pressure fluid pipeline  424 , where the fluid inlets and outlets are arranged in vicinity of the rear portions of the electrically-driven fracturing trailers. Moreover, the low flow-pressure cables and the high flow-pressure cables are electrically connected to the electrical interfaces of the electrically-driven fracturing units  20 , where the electrical interfaces are also arranged in the vicinity of the rear portions of the electrically-driven fracturing trailers. Such arrangement has the advantage of simplifying the distribution arrangement of the electrically-driven fracturing trailers, thereby simplifying the electrical connection process and reducing hindrances for moving the electrically-driven fracturing trailers. 
     In a preferred embodiment, the generator set  10  may be a gas turbine generator set, and a fuel consumed by the gas turbine generator set may be a compressed natural gas (CNG), a liquefied natural gas (LNG) or a wellhead gas. 
     Through the high and low pressure manifold liquid supply system according to the present disclosure, the electrically-driven fracturing units are powered, in this way, the layout of the electricity supply and distribution system of the well site can be effectively simplified, the connection distance of the cables can be shorten, and the time spent on connection can be saved, thereby improving the well site arranging efficiency. In the meantime, since the circuit connections and the fracturing fluid connections are both provided at the rear portions of the electrically-driven fracturing trailers, they will not impact the movement of the electrically-driven fracturing trailers, thus enabling easy detachment from the well site. 
     The foregoing description on the various embodiments of the present disclosure has been presented to those skilled in the relevant fields for the purpose of illustration, but is not intended to be exhaustive or limited to a single embodiment disclosed herein. As aforementioned, many substitutions and variations will be apparent to those skilled in the art. Therefore, although some alternative embodiments have been described above, those skilled in the art can envision or develop other embodiments according to the present disclosure. The present disclosure is intended to cover all substitutions, modifications and variations of the embodiments described herein, as well as other embodiments falling into the spirits and scope of the present disclosure.