HYDRAULIC FRACTURING SYSTEM AND METHOD |
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申请号 | US14950929 | 申请日 | 2015-11-24 | 公开(公告)号 | US20160108712A1 | 公开(公告)日 | 2016-04-21 |
申请人 | Gary C. Walls; | 发明人 | Gary C. Walls; | ||||
摘要 | A hydraulic fracturing system and method are disclosed. The system can include a manifold having a first fluid outlet, a second fluid outlet, and a plurality of fluid inlets. The system can also include primary pumps, which are fluidically coupled to one of the fluid inlets, wherein the primary pumps are configured to deliver a first fluid stream to the first fluid outlet and a second fluid stream to the second fluid outlet. The system can further include a supplemental pump fluidically coupled to the second fluid outlet, wherein the supplemental pump is configured to deliver pulses of fluid to the first fluid stream. | ||||||
权利要求 | We claim: |
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说明书全文 | This non-provisional patent application is a continuation application under 35 U.S.C. §120 of U.S. patent application Ser. No. 14/515,896, entitled HYDRAULIC FRACTURING SYSTEM AND METHOD, filed Oct. 16, 2014, the entire disclosure of which is hereby incorporated by reference herein. The present disclosure relates to hydraulic fracturing systems and methods for assembling and using the same. Hydraulic fracturing can be used to stimulate and/or increase production from oil and gas wells. In a hydraulic fracturing process, fracturing fluid is pumped into a wellbore. Inside the wellbore, hydraulic pressure is employed to force the fracturing fluid into a formation. When the fracturing fluid enters the formation, the formation can fracture and channels and/or fissures can be created within the formation. Fracturing fluid can be pumped into the fractured formation to expand the fissures and/or to increase the size and/or quantity of fissures in the formation. The fracturing fluid can include water, chemicals, and proppants, such as sand, metal, and/or glass beads, for example, which can hold the fissures open. Because hydraulic fracturing can create fissures within a formation and can hold the fissures open, hydraulic fracturing can stimulate the release of oil and gas from the formation. The equipment, including the pump(s), conduit(s), and/or manifold(s), for example, utilized in a hydraulic fracturing operation can operate up to and/or be rated to operate below a pressure threshold or maximum pressure Pmax. In certain instances, the maximum pressure Pmax can be limiting factor in a hydraulic fracturing operation. For example, when a hydraulic fracturing system is operated at its maximum pressure (Pmax), significant volumes of oil and/or gas may remain in the well. In such instances, it can be desirable to improve the effectiveness of a hydraulic fracturing operation, such that additional volumes of gas and/or oil can be extracted from the well, while operating below the maximum pressure (Pmax) of the equipment. Additionally, it can be desirable to extract gas and/or oil from the well using less water and/or less fracturing fluids, with reduced horsepower requirements and/or reduced emissions, and/or in fewer stages and/or more quickly. Additionally, it can be desirable to utilize hydraulic fracturing processes in expanded and/or additional areas. It can also be desirable to reduce the costs of hydraulic fracturing operations, reduce the static pressure required to fracture the formations and/or force the fracturing fluid into the formations, and/or improve the safety conditions at a hydraulic fracturing site. Moreover, it can be desirable to provide real time feedback information to the operators of the hydraulic fracturing equipment. The foregoing discussion is intended only to illustrate various aspects of the related art in the field at the time and should not be taken as a disavowal of claim scope. In at least one form, a hydraulic fracturing system comprises a manifold comprising a first fluid outlet, a second fluid outlet, and a plurality of fluid inlets. The hydraulic fracturing system further comprises a plurality of primary pumps, wherein each of the primary pumps is fluidically coupled to one of the fluid inlets, wherein the primary pumps are configured to deliver a first fluid stream to the first fluid outlet, and wherein the primary pumps are configured to deliver a second fluid stream to the second fluid outlet. The hydraulic fracturing system further comprises a supplemental pump fluidically coupled to the second fluid outlet, wherein the supplemental pump is configured to deliver pulses of fluid to the first fluid stream. In at least one form, the manifold further comprises a supplemental inlet that is fluidically coupled to the supplemental pump. In at least one form, the hydraulic fracturing system further comprises a conduit extending from the first outlet to a wellhead. Additionally, in at least one form, the supplemental pump is fluidically coupled to the conduit. Moreover, in at least one form, the supplemental pump is fluidically coupled to the wellhead. In at least one form, the supplemental pump comprises a first supplemental pump, wherein the hydraulic fracturing system further comprises a second supplemental pump fluidically coupled to the second fluid outlet, and wherein the second supplemental pump is configured to deliver pulses of fluid to the first fluid stream. Additionally, in at least one form, the hydraulic fracturing system further comprises a controller in signal communication with the first supplemental pump and the second supplemental pump. Moreover, in at least one form, the first supplemental pump is configured to deliver pulses of a first magnitude at a first frequency, and the second supplemental pump is configured to deliver pulses of a second magnitude at a second frequency. In at least one form, the first magnitude is different than the second magnitude. In at least one form, the first frequency is different than the second frequency. In at least one form, the fluid stream comprises hydraulic fracturing fluid. In at least one form, each primary pump comprises a piston pump. In at least one form, the hydraulic fracturing system further comprising a plurality of motors operably coupled to the primary pumps and the supplemental pump. In at least one form, a hydraulic fracturing system comprises a manifold comprising a first fluid outlet, a second fluid outlet, and a fluid inlet. The hydraulic fracturing system further comprises a primary pump fluidically coupled to the fluid inlet, wherein the primary pump is configured to deliver a fluid stream to the manifold, wherein a first portion of the fluid stream is directed toward the first fluid outlet, and wherein a second portion of the fluid stream is directed toward the second fluid outlet. The hydraulic fracturing system further comprises a supplemental pump fluidically coupled to the second fluid outlet, wherein the supplemental pump is configured to receive the second portion of the fluid stream and generate pulses of fluid in the second portion of the fluid stream, and wherein the pulses are delivered to the first portion of the fluid stream. The hydraulic fracturing system also comprises a controller in signal communication with the supplemental pump, wherein the controller is configured to control the pulses of fluid from the supplemental pump. In at least one form, the supplemental pump comprises a first supplemental pump, wherein the hydraulic fracturing system further comprises a second supplemental pump arranged in parallel with the first supplemental pump. Additionally, in at least one form, the hydraulic fracturing system further comprises a controller in signal communication with the first supplemental pump and the second supplemental pump. Moreover, in at least one form, the first supplemental pump is configured to deliver pulses of a first magnitude at a first frequency, and the second supplemental pump is configured to deliver pulses of a second magnitude at a second frequency. In at least one form, the first magnitude is different than the second magnitude, and the first frequency is different than the second frequency. In at least one form, a hydraulic fracturing method comprises, generating a fluid stream from a primary pumping system, directing a first portion of the fluid stream to a primary fluid path, diverting a second portion of the fluid stream to a supplemental fluid path, generating a pulsed output from the second portion of the fluid stream, and directing the pulsed output into the first portion of the fluid stream upstream of a wellhead. In at least one form, the hydraulic fracturing method further comprises controlling a supplemental pumping system that is configured to generate the pulsed output from the second portion of the fluid stream. Various features and advantages and the manner of attaining them will become more apparent and will be better understood by reference to the following description of embodiments in conjunction with the accompanying drawings, in which: Certain exemplary embodiments will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the devices, systems, and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the various embodiments is defined solely by the claims. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present disclosure. Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment”, or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment”, or “in an embodiment”, or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Additionally, reference throughout the specification to “various instances,” “some instances,” “one instance,” or “an instance”, or the like, means that a particular feature, structure, or characteristic described in connection with the instance is included in at least one instance. Thus, appearances of the phrases “in various instances,” “in some instances,” “in one instance”, “in an instance”, or the like, in places throughout the specification are not necessarily all referring to the same instance. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiment or instance. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment or instance may be combined, in whole or in part, with the features structures, or characteristics of one or more other embodiment or instance without limitation. Such modifications and variations are intended to be included within the scope of the present disclosure. The primary pumps 110 can be high-pressure, high-volume fracturing pumps. In certain instances, the primary pumps 110 can be piston pumps. For example, the pumps 110 can be triplex or quintuplex piston pumps. The primary pumps 110 can be rated up to 22,000 psi and 115 gallons per minute, for example. At a lower value psi, the primary pumps 100 can be rated up to 1375 gallons per minute, for example. In various instances, the primary pumps 110 can be portable or mobile, for example. For example, each primary pump 110 can be mounted to a vehicle 112, such as a truck or a trailer, for example. In certain instances, the primary pumps 110 can be moved around the hydraulic fracturing site and/or can be relocated to different hydraulic fracturing sites. In some instances, multiple primary pumps 110 can be mounted to each vehicle 112. Referring to Referring still to The primary pumps 110 can be fluidically connected to the wellhead 116 via fluid lines 120, the manifold 118, and/or a conduit 122. For example, the vehicles 112 can be positioned near enough to the manifold 118 such that a fluid line 120 connects each primary pump 110 to the manifold 118. The manifold 118 can include a plurality of inlets 130 and an outlet 132. In certain instances, the inlets 130 can be equally-spaced along the length of the manifold 118. In other instances, at least two inlets 130 can be unequally spaced. Additionally or alternatively, an inlet 130 can be positioned at an end of the manifold 118. Referring to the embodiment depicted in Fracturing fluid can flow along a fluid path or stream within the manifold 118. Referring to Various components of fracturing fluid can be supplied to the primary pumps 110. For example, water, chemicals, and/or proppants can be supplied to one or more of the primary pumps 110. In certain instances, the hydraulic fracturing fluid supplied to the primary pumps 110 can be pre-mixed. For example, a slurry blender can mix various components, and the mixture can be fed into one or more of the primary pumps 110. In some instances, at least one primary pump 110 in the system 100 can be coupled to a water supply, at least one primary pump 110 in the system 100 can be coupled to a chemical supply, and/or at least one pump 110 in the system can be coupled to a proppant supply. For example, referring to Proppants can include sand, metal and/or glass beads, and/or other solid material, for example. The proppants can be various sizes, and multiple different size proppants can be included in a hydraulic fracturing fluid. Chemical additives can include lubricants, for example. In various instances, chemical additives and/or proppants can comprise approximately 0.5% of the total volume of fracturing fluid delivered to the wellhead 116. The hydraulic fracturing system 100 may also include blenders or mixers, which can be configured to mix and blend the components of the hydraulic fracturing fluid, and to supply the hydraulic fracturing fluid to the primary pumps 110. Water, chemicals, and/or proppants can be supplied to the system 100 by additional vehicles, conduits, and/or conveyors. The hydraulic fracturing system 100 can further include at least one monitoring unit, which can monitor the composition and properties of the fracturing fluid, the volume of various supplies, and/or the flow rate, density, and/or pressure of the fracturing fluid at various locations within the system 100. Referring still to In certain instances, the generation and introduction of pulses or waves of fracturing fluid into the fluid stream can improve the effectiveness of the hydraulic fracturing operation. For example, pulses of fracturing fluid can create additional fissures within a formation and/or can enlarge preexisting fractures. More specifically, pulses of fracturing fluid can force a proppant, such as sand, for example, further down the borehole and into the formation to further enlarge the width and/or extend the length of the fissure and to hold the fissure open. Because pulses of fracturing fluid can expand the fractured region, the addition of pulses to a fracturing operation can generate more oil and/or gas from the well. The addition of pulses can also extend hydraulic fracturing to areas where it would otherwise be cost prohibitive. A pulse of fracturing fluid can also provide a pressure shock signal to the operator. For example, microseismic energy measurement device(s) at the surface can measure the microseismic events and/or conditions within and around the wellbore. The device can then communicate the measurements to the operator in real time. The pulses of fracturing fluid within the fluid stream can be mechanically induced. For example, a supplemental pump can generate a mechanical pulse or wave of fracturing fluid, which can be fed into the fluid stream. In certain instances, the supplemental pump can provide periodic pulses, for example, which can generate corresponding periodic pressure increases or spikes within the fluid stream. In other instances, the pulses can be intermittent and/or sporadic. An operator can control the supplemental pump to deliver pulses periodically and/or sporadically, for example. In certain instances, multiple supplemental pumps can be configured to generate pulses of fracturing fluid, which can be delivered to the fluid stream. The pulses can be output from different supplemental pumps and can have different frequencies and/or different amplitudes, for example. In various instances, the pulses from different supplemental pumps can overlap, and/or can concurrently join the fluid stream. In other instances, the pulses can be staggered and/or can intermittently join the fluid stream. In certain instances, at least one supplemental pump can be configured to deliver small pulses to the fluid stream, and at least one supplemental pump can be configured to deliver larger pulses to the fluid stream. Large pulses of fracturing fluid can break apart rock formations, thus providing more channels and/or fissures within the formation. Additionally, large pulses of fracturing fluid can stimulate proppants and lubricants in the fracturing fluid, and can force additional proppants and lubricants within the fissures. Large pulses of fracturing fluid can also increase abrasion within the fissures, which can further enlarge a fissure. Moreover, large pulses of fracturing fluid can provide a shock signal to the operator. Small pulses of fracturing fluid can also stimulate proppants in the fracturing fluid, which can force additional proppants within the fissures. As proppants are forced further into the fissures, the fissures can be enlarged. Additionally, the small pulses of fracturing fluid can also provide a shock signal to the operator. Referring now to Referring still to The supplemental pump 240 can be in fluid communication with the manifold 218 via a supplemental outlet 234 to the manifold 218 and a supplemental conduit 238. For example, a first portion of the fluid stream that is injected or pumped into the manifold 218 from the primary pumps 110 via the fluid lines 120 can flow from the inlets 230 toward the primary outlet 232. Additionally, a second portion of the fluid stream that is injected or pumped into the manifold 218 from the primary pumps 110 can be diverted to the supplemental outlet 234. The second portion of the fluid stream can flow to the supplemental pump 240, for example. In various instances, the supplemental pump 240 can be configured to induce at least one pulse of fluid into the fluid stream. For example, the supplemental pump 240 can generate a pulse of fracturing fluid, which can flow from the pump 240 through a connecting conduit 242. Thereafter, the mechanically-induced pulse of fluid can join the fluid stream generated by the primary pumps 110. The mechanically-induced pulse or pulses generated by the supplemental pump 240 can be generated outside of the wellbore, for example, and can be transmitted to the fluid stream outside of the wellbore, for example. In various instances, the pulse or pulses can enter the fluid stream downstream of the plurality of inlets 230 to the manifold 218. For example, the pulses can be introduced to the fluid stream between the manifold 218 and the wellhead 116. In various instances, the supplemental pump 240 can transmit the mechanically-induced pulses to the connecting conduit 242, and the connecting conduit 242 can be coupled to the primary conduit 222. For example, the connecting conduit 242 and the primary conduit 222 can be coupled at a supplemental manifold or union intermediate the manifold 218 and the wellhead 116. In other instances, a supplemental, pulse-generating pump can transmit the pulse or pulses to the fluid stream at the wellhead 116. For example, referring to In still other instances, a supplemental, pulse-generating pump can transmit the pulse or pulses to the fluid stream within the manifold. For example, referring to In various pump arrangements described herein, the supplemental pump 240 ( In certain instances 5%-50% of the fluid from the primary pumps 110 can be diverted to the supplemental pump 240. For example, approximately 25% of the fluid from the primary pumps 110 can be diverted to the supplemental pump 240. In other words, as an example, if 80 barrel units were pumped into the manifold 218 ( In various arrangements, the primary pumps 110 can generate a maximum pressure in the manifold 218 ( In various instances, a hydraulic fracturing system can include one or more supplemental pulse-inducing pumps. A hydraulic fracturing system 500 is depicted in In other instances, similar to the system 200, the connecting conduits 542a, 542b and the primary conduit 222 can be coupled at a supplemental manifold or union intermediate the manifold 218 and the wellhead 116. In still other instances, similar to the system 300, the connecting conduits 542a, 542b can transmit the pulses to the fluid stream at the wellhead 116. Additionally or alternatively, the connecting conduits 542a, 542b can be in fluid connection with the fluid stream at different locations downstream of the inlets 230. For example, the first connecting conduit 542a can be coupled to the fluid stream upstream of the second connecting conduit 542b. Moreover, the system 500 can include additional supplemental pumps. For example, the system 500 can include three or more supplemental, pulse-generating pumps. Referring to Referring to Additionally or alternatively, the pulse frequency of the second pulsed output 740 can be greater than the pulse frequency of the first pulsed output 640, for example. For example, the pulse frequency of the second pulsed output 740 can be two (2) to ten (10) times greater than the pulse frequency of the first pulsed output 640. In the depicted instances, the pulse frequency of the second pulsed output 740 is three (3) times greater than the pulse frequency of the first pulsed output 640. In other instances, referring to Referring again to Referring still to In other instances, referring now to In an exemplary embodiment, referring again to In various instances, the supplemental, pulse-inducing pump or pumps of a hydraulic fracturing system can be in signal communication with a controller. For example, referring again to Referring now to Referring still to At step 1020, the pulsed output from the supplemental pump system can be directed into the first portion of the fluid stream. For example, the pulsed output can be pumped into the first portion of the fluid stream at the manifold, at the wellhead, and/or between the manifold and the wellhead. As a result, the combined fluid stream can enter the wellhead and be forced down the wellbore and into the formation. Throughout the steps 1010, 1012, 1014, 1016 and 1020 described above, a monitoring unit can monitor the fluid stream from the primary pumping system and the supplemental pumping system. Moreover, a controller can control the primary and/or supplemental pumps throughout the steps 1010, 1012, 1014, 1016 and 1020. For example, the pulsing sequences, including frequency and/or amplitude, for example, can be adjusted throughout the process. The reader will appreciate that the various hydraulic fracturing systems and methods described herein can be employed in new wells and can be utilized at previously drilled wells to draw out additional oil and/or gas, for example. Additionally, the systems and methods described herein can employ various pumps simultaneously and/or separately. In various instances, it may be advantageous to exclusively employ the supplemental pump(s) described herein for at least a portion of a hydraulic fracturing operation. In such instances, the entire fluid stream from the primary pumps 110 can be diverted to a supplemental pump or pumps. Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. While the hydraulic fracturing systems and/or methods have been described as having exemplary designs, the present invention may be further modified within the spirit and scope of the disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains. |