USRE49456E1 - Methods of performing oilfield operations using electricity - Google Patents

Abstract

Methods and systems for integral storage and blending of the materials used in oilfield operations are disclosed. A modular integrated material blending and storage system includes a first module comprising a storage unit, a second module comprising a liquid additive storage unit and a pump for maintaining pressure at an outlet of the liquid additive storage unit. The system further includes a third module comprising a pre-gel blender. An output of each of the first module, the second module and the third module is located above a blender and gravity directs the contents of the first module, the second module and the third module to the blender. The system also includes a pump that directs the output of the blender to a desired down hole location. The pump may be powered by natural gas or electricity.

Description

Notice: More than one reissue application has been filed for the reissue of U.S. Pat. No. 8,834,012. The reissue applications are U.S. patent application Ser. No. 15/079,027, now U.S. Pat. No. RE46,725, which is a reissue application of U.S. Pat. No. 8,834,012; U.S. patent application Ser. No. 15/853,076, now U.S. Pat. No. RE47,695, which is a reissue of U.S. Pat. No. 8,834,012 and is a divisional reissue application of U.S. patent application Ser. No. 15/079,027, now U.S. Pat. No. RE46,725; U.S. patent application Ser. No. 16/537,070, which is a continuation reissue application of U.S. patent application Ser. No. 15/853,076, now U.S. Pat. No. RE47,695, and a reissue of U.S. Pat. No. 8,834,012; U.S. patent application Ser. No. 16/537,124, which is a continuation reissue application of U.S. patent application Ser. No. 15/853,076, now U.S. Pat. No. RE47,695, and a reissue of U.S. Pat. No. 8,834,012; the present U.S. patent application Ser. No. XX/XXX,XXX 17/353,091, which is a continuation reissue application of U.S. patent application Ser. No Nos. 16/537,070 and 16/537,124 and a reissue of U.S. Pat. No. 8,834,012; and the following U.S. patent application Ser. Nos. XX/XXX,XXX, XX/XXX,XXX, XX/XXX,XXX, XX/XXX,XXX, XX/XXX,XXX, XX/XXX,XXX, XX/XXX,XXX, and XX/XXX,XXX 17/221,152, 17/221,176, 17/221,186, 17/221,204, 17/221,221, 17/221,242, 17/221,267, 17/221,281, 17/221,317, and 17/353,091, each of which is a continuation reissue application of U.S. patent application Ser. No. Nos. 16/537,070 and 16/537,124 and a reissue of U.S. Pat. No. 8,834,012.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation reissue of U.S. patent application Ser. No. 16/537,070 and U.S. patent application Ser. No. 16/537,124, both filed on Aug. 9, 2019, which are reissue applications of U.S. Pat. No. 8,834,012 and continuation reissue applications of U.S. patent application Ser. No. 15/853,076, filed on Dec. 22, 2017, now U.S. Pat. No. RE47,695, which is a reissue of U.S. Pat. No. 8,834,012 and a divisional reissue application of U.S. patent application Ser. No. 15/079,027, filed on Mar. 23, 2016, now U.S. Pat. No. RE46,725, which is a reissue application of U.S. patent application Ser. No. 12/744,959, filed on May 6, 2010, now U.S. Pat. No. 8,834,012, issued on Sep. 16, 2014, entitled “Electric or Natural Gas Fired Small Footprint Fracturing Fluid Blending and Pumping Equipment,” which is a continuation-in-part of U.S. patent application Ser. No. 12/557,730, filed Sep. 11, 2009, now U.S. Pat. No. 8,444,312, issued on May 21, 2013, entitled “Improved Methods and Systems for Integral Blending and Storage of Materials,” the entire disclosures of which are incorporated herein by reference.

BACKGROUND

The present invention relates generally to oilfield operations, and more particularly, to methods and systems for integral storage and blending of the materials used in oilfield operations.

Oilfield operations are conducted in a variety of different locations and involve a number of equipments, depending on the operations at hand. The requisite materials for the different operations are often hauled to and stored at the well site where the operations are to be performed.

Considering the number of equipments necessary for performing oilfield operations and ground conditions at different oilfield locations, space availability is often a constraint. For instance, in well treatment operations such as fracturing operations, several wells may be serviced from a common jobsite pad. In such operations, the necessary equipment is not moved from well site to well site. Instead, the equipment may be located at a central work pad and the required treating fluids may be pumped to the different well sites from this central location. Accordingly, the bulk of materials required at a centralized work pad may be enormous, further limiting space availability.

Typically, in modem well treatment operations, equipment is mounted on a truck or a trailer and brought to location and set up. The storage units used are filled with the material required to prepare the well treatment fluid and perform the well treatment. In order to prepare the well treatment fluid, the material used is then transferred from the storage units to one or more blenders to prepare the desired well treatment fluid which may then be pumped down hole.

For instance, in conventional fracturing operations a blender and a pre-gel blender are set between the high pressure pumping units and the storage units which contain the dry materials and chemicals used. The dry materials and the chemicals used in the fracturing operations are then transferred, often over a long distance, from the storage units to the mixing and blending equipments. Once the treating process is initiated, the solid materials and chemicals are typically conveyed to the blender by a combination of conveyer belts, screw type conveyers and a series of hoses and pumps.

The equipment used for transferring the dry materials and chemicals from the storage units to the blender occupy valuable space at the job site. Additionally, the transfer of dry materials and chemicals to the blender consumes a significant amount of energy as well as other system resources and contributes to the carbon foot print of the job site. Moreover, in typical “on land” operations the entire equipment spread including the high horsepower pumping units are powered by diesel fired engines and the bulk material metering, conveying and pumping is done with diesel fired hydraulic systems. Emissions from the equipment that is powered by diesel fuel contributes to the overall carbon footprint and adversely affects the environment.

FIGURES

Some specific example embodiments of the disclosure may be understood by referring, in part, to the following description and the accompanying drawings.

FIG.1 is a top view of an Integrated Material Storage and Blending System in accordance with an exemplary embodiment of the present invention.

FIG.2 is a cross sectional view of an Integrated Pre-gel Blender in accordance with a first exemplary embodiment of the present invention.

FIG.3 is a cross sectional view of an Integrated Pre-gel Blender in accordance with a second exemplary embodiment of the present invention.

FIG.4 is a cross sectional view of an Integrated Pre-gel Blender in accordance with a third exemplary embodiment of the present invention.

FIG.5 depicts a close up view of the interface between the storage units and a blender in an Integrated Material Storage and Blending System in accordance with an exemplary embodiment of the present invention.

FIG.6 is an isometric view of an Integrated Material Storage and Blending System in accordance with an exemplary embodiment of the present invention.

FIG. 7 is a diagram illustrating a pumping system in accordance with an exemplary embodiment of the present invention.

While embodiments of this disclosure have been depicted and described and are defined by reference to example embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only, and not exhaustive of the scope of the disclosure.

SUMMARY

The present invention relates generally to oilfield operations, and more particularly, to methods and systems for integral storage and blending of the materials used in oilfield operations.

In one embodiment, the present invention is directed to an integrated material blending and storage system comprising: a storage unit; a blender located under the storage unit; wherein the blender is operable to receive a first input from the storage unit; a liquid additive storage module having a pump to maintain constant pressure at an outlet of the liquid additive storage module; wherein the blender is operable to receive a second input from the liquid additive storage module; and a pre-gel blender; wherein the blender is operable to receive a third input from the pre-gel blender; wherein gravity directs the contents of the storage unit, the liquid additive storage module and the pre-gel blender to the blender; a first pump; and a second pump; wherein the first pump directs the contents of the blender to the second pump; and wherein the second pump directs the contents of the blender down hole; wherein at least one of the first pump and the second pump is powered by one of natural gas and electricity.

In another exemplary embodiment, the present invention is directed to a modular integrated material blending and storage system comprising: a first module comprising a storage unit; a second module comprising a liquid additive storage unit and a pump for maintaining pressure at an outlet of the liquid additive storage unit; and a third module comprising a pre-gel blender; wherein an output of each of the first module, the second module and the third module is located above a blender; and wherein gravity directs the contents of the first module, the second module and the third module to the blender; a pump; wherein the pump directs the output of the blender to a desired down hole location; and wherein the pump is powered by one of natural gas and electricity.

The features and advantages of the present disclosure will be readily apparent to those skilled in the art upon a reading of the description of exemplary embodiments, which follows.

DESCRIPTION

The present invention relates generally to oilfield operations, and more particularly, to methods and systems for integral storage and blending of the materials used in oilfield operations.

Turning now toFIG.1, an Integrated Material Storage and Blending System (IMSBS) in accordance with an exemplary embodiment of the present invention is depicted generally withreference numeral100. TheIMSBS100 includes a number ofstorage units102. Thestorage units102 may contain sand, proppants or other solid materials used to prepare a desired well treatment fluid.

In one exemplary embodiment, thestorage units102 may be connected to load sensors (not shown) to monitor the reaction forces at the legs of thestorage units102. The load sensor readings may then be used to monitor the change in weight, mass and/or volume of materials in thestorage units102. The change in weight, mass or volume can be used to control the metering of material from thestorage units102 during well treatment operations. As a result, the load sensors may be used to ensure the availability of materials during oilfield operations. In one exemplary embodiment, load cells may be used as load sensors. Electronic load cells are preferred for their accuracy and are well known in the art, but other types of force-measuring devices may be used. As will be apparent to one skilled in the art, however, any type of load-sensing device can be used in place of or in conjunction with a load cell. Examples of suitable load-measuring devices include weight-, mass-, pressure- or force-measuring devices such as hydraulic load cells, scales, load pins, dual sheer beam load cells, strain gauges and pressure transducers. Standard load cells are available in various ranges such as 0-5000 pounds, 0-10000 pounds, etc.

In one exemplary embodiment the load sensors may be communicatively coupled to aninformation handling system104 which may process the load sensor readings. WhileFIG.1 depicts a separateinformation handling system104 for eachstorage unit102, as would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, a single information handling system may be used for all or any combination of thestorage units102. AlthoughFIG.1 depicts a personal computer as theinformation handling system104, as would be apparent to those of ordinary skill in the art, with the benefit of this disclosure, theinformation handling system104 may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, theinformation handling system104 may be a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. For instance, in one exemplary embodiment, theinformation handling system104 may be used to monitor the amount of materials in thestorage units102 over time and/or alert a user when the contents of astorage unit102 reaches a threshold level. The user may designate a desired sampling interval at which theinformation handling system104 may take a reading of the load sensors.

Theinformation handling system104 may then compare the load sensor readings to the threshold value to determine if the threshold value is reached. If the threshold value is reached, theinformation handling system104 may alert the user. In one embodiment, theinformation handling system104 may provide a real-time visual depiction of the amount of materials contained in thestorage units102. Moreover, as would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, the load sensors may be coupled to theinformation handling system104 through a wired or wireless (not shown) connection.

As depicted inFIG.1, theIMSBS100 may also include one or more Integrated Pre-gel Blenders (IPB)106. TheIPB106 may be used for preparing any desirable well treatment fluids such as a fracturing fluid, a sand control fluid or any other fluid requiring hydration time.

FIG.2 depicts anIPB200 in accordance with an exemplary embodiment of the present invention. TheIPB200 comprises apre-gel storage unit202 resting onlegs204. As would be appreciated by those of ordinary skill in the art, thepre-gel storage unit202 may be a storage bin, a tank, or any other desirable storage unit. Thepre-gel storage unit202 may contain the gel powder used for preparing the gelled fracturing fluid. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, the gel powder may comprise a dry polymer. Specifically, the dry polymer may be any agent used to enhance fluid properties, including, but not limited to, wg18, wg35, wg36 (available from Halliburton Energy Services of Duncan, Okla.) or any other guar or modified guar gelling agents. The materials from thepre-gel storage unit202 may be directed to amixer206 as a first input through afeeder208. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, in one embodiment, themixer206 may be a growler mixer and thefeeder208 may be a screw feeder which may be used to provide a volumetric metering of the materials directed to themixer206. Awater pump210 may be used to supply water to themixer206 as a second input. A variety of different pumps may be used as thewater pump210 depending on the user preferences. For instance, thewater pump210 may be a centrifugal pump, a progressive cavity pump, a gear pump or a peristaltic pump. Themixer206 mixes the gel powder from thepre-gel storage unit202 with the water from thewater pump210 at the desired concentration and the finished gel is discharged from themixer206 and may be directed to a storage unit, such as an external frac tank (not shown), for hydration. The finished gel may then be directed to ablender108 in theIMSBS100.

In one exemplary embodiment, thelegs204 of thepre-gel storage unit202 are attached to loadsensors212 to monitor the reaction forces at thelegs204. Theload sensor212 readings may then be used to monitor the change in weight, mass and/or volume of materials in thepre-gel storage unit202. The change in weight, mass or volume can be used to control the metering of material from thepre-gel storage unit202 at a given set point. As a result, theload sensors212 may be used to ensure the availability of materials during oilfield operations. In one exemplary embodiment, load cells may be used asload sensors212. Electronic load cells are preferred for their accuracy and are well known in the art, but other types of force-measuring devices may be used. As will be apparent to one skilled in the art, however, any type of load-sensing device can be used in place of or in conjunction with a load cell. Examples of suitable load-measuring devices include weight-, mass-, pressure- or force-measuring devices such as hydraulic load cells, scales, load pins, dual sheer beam load cells, strain gauges and pressure transducers. Standard load cells are available in various ranges such as 0-5000 pounds, 0-10000 pounds, etc.

In one exemplary embodiment theload sensors212 may be communicatively coupled to aninformation handling system214 which may process the load sensor readings. AlthoughFIG.2 depicts a personal computer as theinformation handling system214, as would be apparent to those of ordinary skill in the art, with the benefit of this disclosure, theinformation handling system214 may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, theinformation handling system214 may be a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. For instance, in one exemplary embodiment, theinformation handling system214 may be used to monitor the amount of materials in thepre-gel storage unit202 over time and/or alert a user when the contents of thepre-gel storage unit202 reaches a threshold level. The user may designate a desired sampling interval at which theinformation handling system214 may take a reading of theload sensors212. Theinformation handling system214 may then compare the load sensor readings to the threshold value to determine if the threshold value is reached. If the threshold value is reached, theinformation handling system214 may alert the user. In one embodiment, theinformation handling system214 may provide a real-time visual depiction of the amount of materials contained in thepre-gel storage unit202.

Moreover, as would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, theload sensors212 may be coupled to theinformation handling system214 through a wired or wireless (not shown) connection. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, in one exemplary embodiment, the dry polymer material may be replaced with a Liquid Gel Concentrate (“LGC”) material that consists of the dry polymer mixed in a carrier fluid. In this exemplary embodiment, the feeder and mixer mechanisms would be replaced with a metering pump of suitable construction to inject the LGC into the water stream, thus initiating the hydration process.

FIG.3 depicts an IPB in accordance with a second exemplary embodiment of the present invention, denoted generally byreference numeral300. TheIPB300 comprises apre-gel storage unit302 resting onlegs308. Thepre-gel storage unit302 in this embodiment may include acentral core304 for storage and handling of materials. In one embodiment, thecentral core304 may be used to store a dry gel powder for making gelled fracturing fluids. Thepre-gel storage unit302 may further comprise anannular space306 for hydration volume. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, the gel powder may comprise a dry polymer. Specifically, the dry polymer may comprise a number of different materials, including, but not limited to, wg18, wg35, wg36 (available from Halliburton Energy Services of Duncan, Okla.) or any other guar or modified guar gelling agents.

The materials from thecentral core304 of thepre-gel storage unit302 may be directed to amixer310 as a first input through afeeder312. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, in one embodiment, themixer310 may be a growler mixer and thefeeder312 may be a screw feeder which may be used to provide a volumetric metering of the materials directed to themixer310. Awater pump314 may be used to supply water to themixer310 as a second input. A variety of different pumps may be used as thewater pump314 depending on the user preferences. For instance, thewater pump314 may be a centrifugal pump, a progressive cavity pump, a gear pump or a peristaltic pump. Themixer310 mixes the gel powder from thepre-gel storage unit302 with the water from thewater pump314 at the desired concentration and the finished gel is discharged from themixer310. As discussed above with reference to thestorage units102, thepre-gel storage unit302 may rest onload sensors316 which may be used for monitoring the amount of materials in thepre-gel storage unit302. The change in weight, mass or volume can be used to control the metering of material from thepre-gel storage unit302 at a given set point.

In this embodiment, once the gel having the desired concentration is discharged from themixer310, it is directed to theannular space306. The gel mixture is maintained in theannular space306 for hydration. Once sufficient time has passed and the gel is hydrated, it is discharged from theannular space306 through thedischarge line318.

FIG.4 depicts a cross sectional view of a storage unit in anIPB400 in accordance with a third exemplary embodiment of the present invention. TheIPB400 comprises apre-gel storage unit402 resting onlegs404. Thepre-gel storage unit402 in this embodiment may include acentral core406 for storage and handling of materials. In one embodiment, thecentral core406 may be used to store a dry gel powder for making gelled fracturing fluids. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, the gel powder may comprise a dry polymer. Specifically, the dry polymer may be any agent used to enhance fluid properties, including, but not limited to, wg18, wg35, wg36 (available from Halliburton Energy Services of Duncan, Okla.) or any other guar or modified guar gelling agents. Thepre-gel storage unit402 may further comprise anannular space408 which may be used as a hydration volume. In this embodiment, theannular space408 contains atubular hydration loop410.

The materials from thecentral core406 of thepre-gel storage unit402 may be directed to amixer412 as a first input through afeeder414. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, in one embodiment, themixer412 may be a growler mixer and thefeeder414 may be a screw feeder which may be used to provide a volumetric metering of the materials directed to themixer412. Awater pump416 may be used to supply water to themixer412 as a second input. A variety of different pumps may be used as thewater pump416 depending on the user preferences. For instance, thewater pump416 may be a centrifugal pump, a progressive cavity pump, a gear pump or a peristaltic pump. Themixer412 mixes the gel powder from thepre-gel storage unit402 with the water from thewater pump416 at the desired concentration and the finished gel is discharged from themixer412. As discussed above with reference toFIG.1, thepre-gel storage unit402 may rest onload sensors418 which may be used for monitoring the amount of materials in thepre-gel storage unit402. The change in weight, mass or volume can be used to control the metering of material from thepre-gel storage unit402 at a given set point.

In this embodiment, once the gel having the desired concentration is discharged from themixer412, it is directed to theannular space408 where it enters thetubular hydration loop410. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, the portions of the gel mixture are discharged from themixer412 at different points in time, and accordingly, will be hydrated at different times. Specifically, a portion of the gel mixture discharged from themixer412 into theannular space408 at a first point in time, t1, will be sufficiently hydrated before a portion of the gel mixture which is discharged into theannular space408 at a second point in time, t2. Accordingly, it is desirable to ensure that the gel mixture is transferred through theannular space408 in a First-In-First-Out (FIFO) mode. To that end, in the third exemplary embodiment, atubular hydration loop410 is inserted in theannular space408 to direct the flow of the gel as it is being hydrated.

As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, in order to achieve optimal performance, thetubular hydration loop410 may need to be cleaned during a job or between jobs. In one embodiment, thetubular hydration loop410 may be cleaned by passing a fluid such as water through it. In another exemplary embodiment, a pigging device may be used to clean thetubular hydration loop410.

Returning toFIG.1, theIMSBS100 may include one ormore blenders108 located at the bottom of thestorage units102. In one embodiment,multiple storage units102 may be positioned above ablender108 and be operable to deliver solid materials to theblender108.FIG.5 depicts a close up view of the interface between thestorage units102 and theblender108. As depicted inFIG.5, gravity directs the solid materials from thestorage units102 to theblender108 through thehopper502, obviating the need for a conveyer system.

Returning toFIG.1, theIMSBS100 may also include one or more liquidadditive storage modules110. The liquidadditive storage modules110 may contain a fluid used in preparing the desired well treatment fluid. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, depending on the well treatment fluid being prepared, a number of different fluids may be stored in the liquidadditive storage modules110. Such fluids may include, but are not limited to, surfactants, acids, cross-linkers, breakers, or any other desirable chemical additives. As discussed in detail with respect tostorage units102, load sensors (not shown) may be used to monitor the amount of fluid in the liquidadditive storage modules110 in real time and meter the amount of fluids delivered to theblender108. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, a pump may be used to circulate the contents and maintain constant pressure at the head of the liquidadditive storage modules110. Because the pressure of the fluid at the outlet of the liquidadditive storage modules110 is kept constant and theblender108 is located beneath the liquidadditive storage modules110, gravity assists in directing the fluid from the liquidadditive storage modules110 to theblender108, thereby obviating the need for a pump or other conveyor systems to transfer the fluid.

As depicted in more detail inFIG.5, theblender108 includes afluid inlet112 and anoptional water inlet504. Once the desired materials are mixed in theblender108, the materials exit theblender108 through theoutlet114.

In one embodiment, when preparing a well treatment fluid, a base gel is prepared in theIPB106. In one embodiment, the gel prepared in the IPB may be directed to anannular space406 for hydration. In another exemplary embodiment, the annular space may further include ahydration loop410. In one exemplary embodiment, the resulting gel from theIPB106 may be pumped to the centrally locatedblender108. Each of the base gel, the fluid modifying agents and the solid components used in preparing a desired well treatment fluid may be metered out from theIPB106, the liquidadditive storage module110 and thestorage unit102, respectively. Theblender108 mixes the base gel with other fluid modifying agents from the liquidadditive storage modules110 and the solid component(s) from thestorage units102. As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, when preparing a fracturing fluid the solid component may be a dry proppant. In one exemplary embodiment, the dry proppant may be gravity fed into the blending tub through metering gates. Once theblender108 mixes the base gel, the fluid modifying agent and the solid component(s), the resulting well treatment fluid may be directed to a down hole pump (not shown) through theoutlet114. A variety of different pumps may be used to pump the output of the IMSBS down hole. For instance, the pump used may be a centrifugal pump, a progressive cavity pump, a gear pump or a peristaltic pump. In one exemplary embodiment, chemicals from the liquidadditive storage modules110 may be injected in the manifolds leading to and exiting theblender108 in order to bring them closer to the centrifugal pumps and away from other chemicals when there are compatibility or reaction issues.

As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, the mixing and blending process may be accomplished at the required rate dictated by the job parameters. As a result, pumps that transfer the final slurry to the down hole pumps typically have a high horsepower requirement. FIG. 7 depicts a pumping system in accordance with an exemplary embodiment of the present invention, denoted generally withreference numeral 700. In one exemplary embodiment, shown in FIG. 7, thetransfer pump 702 may be powered by a natural gas fired engine or a natural gas fired generator set 714. In another exemplary embodiment, the transfer pump may be powered by electricity from a power grid. Once the fluid system is mixed and blended with proppant and other fluid modifiers it is boosted to the high horsepower down hole pumps 704. The down hole pumps pump the slurry through the highpressure ground manifold 706 to thewell head 708 and down hole. In one embodiment, the down hole pumps 704 may be powered by a natural gas fired engine, a natural gas fired generator set 714 or electricity from a power grid. The down hole pumps typically account for over two third of the horsepower on location, thereby reducing the carbon footprint of the overall operations.

In one exemplary embodiment, the natural gas used to power the transfer pumps, the down hole pumps or the other system components may be obtained from the field on which the subterranean operations are being performed 720. In one embodiment, the natural gas may be converted to liquefied natural gas and used to power pumps and other equipment that would typically be powered by diesel fuel. In another embodiment, the natural gas may be used to provide power through generator sets 714. The natural gas from the field may undergoconditioning 710 before being used to provide power to the pumps and other equipment. The conditioning process may include cleaning the natural gas, compressing the natural gas in compressor stations and if necessary, removing any water contained therein.

As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, the IMSBS may include a different number ofstorage units102,IPBs106 and/or liquidadditive storage modules110, depending on the system requirements. For instance, in another exemplary embodiment (not shown), the IMSBS may include three storage units, one IPB and one liquid additive storage module.

FIG.6 depicts an isometric view of IMSBS in accordance with an exemplary embodiment of the present invention, denoted generally withreference numeral600. As depicted inFIG.6, each of thestorage units602, each of the liquidadditive storage modules604 and each of theIPBs606 may be arranged as an individual module. In one embodiment, one or more of thestorage units602, the liquidadditive storage modules604 and theIPBs606 may include a latch system which is couplable to a truck or trailer which may be used for transporting the module. In one embodiment, thestorage units602 may be a self-erecting storage unit as disclosed in U.S. patent application Ser. No. 12/235,270, assigned to Halliburton Energy Services, Inc., which is incorporated by reference herein in its entirety. Accordingly, thestorage units602 may be specially adapted to connect to a vehicle which may be used to lower, raise and transport thestorage unit602. Once at a jobsite, thestorage unit602 may be erected and filled with a predetermined amount of a desired material. A similar design may be used in conjunction with each of the modules of theIMSBS600 disclosed herein in order to transport the modules to and from a job site. Once the desired number ofstorage units602, the liquidadditive storage modules604 and theIPBs606 are delivered to a job site, they are erected in their vertical position. Dry materials such as proppants or gel powder may then be filled pneumatically to the desired level and liquid chemicals may be pumped into the various storage tanks. Load sensors (not shown) may be used to monitor the amount of materials added to thestorage units602, the liquidadditive storage modules604 and theIPBs606 in real time.

As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, anIMSBS600 in accordance with an exemplary embodiment of the present invention which permits accurate, real-time monitoring of the contents of thestorage units602, the liquidadditive storage modules604 and/or theIPBs606 provides several advantages. For instance, an operator may use the amount of materials remaining in thestorage units602, the liquidadditive storage modules604 and/or theIPBs606 as a quality control mechanism to ensure that material consumption is in line with the job requirements. Additionally, the accurate, real-time monitoring of material consumption expedites the operator's ability to determine the expenses associated with a job.

As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, the different equipment used in an IMSBS in accordance with the present invention may be powered by any suitable power source. For instance, the equipment may be powered by a combustion engine, electric power supply which may be provided by an on-site generator or by a hydraulic power supply.

Therefore, the present invention is well-adapted to carry out the objects and attain the ends and advantages mentioned as well as those which are inherent therein. While the invention has been depicted and described by reference to exemplary embodiments of the invention, such a reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects. The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee.

Claims (56)

What is claimed is:

1. An integrated material blending and storage system comprising:

a storage unit;

a blender located under the storage unit;

wherein the blender is operable to receive a first input from the storage unit through a hopper;

a liquid additive storage module having a first pump to maintain constant pressure at an outlet of the liquid additive storage module;

wherein the blender is operable to receive a second input from the liquid additive storage module; and

a pre-gel blender, wherein the pre-gel blender comprises at least a pre-gel storage unit resting on a leg, further wherein the pre-gel storage unit comprises a central core and an annular space, wherein the annular space hydrates the contents of the pre-gel blender;

wherein the blender is operable to receive a third input from the pre-gel blender;

wherein gravity directs the contents of the storage unit, the liquid additive storage module and the pre-gel blender to the blender;

a second pump; and

a third pump;

wherein the second pump directs the contents of the blender to the third pump; and

wherein the third pump directs the contents of the blender down hole;

wherein at least one of the second pump and the third pump is powered by one of natural gas and electricity.

2. The system ofclaim 1, wherein the storage unit comprises a load sensor.

3. The system ofclaim 1, wherein the pre-gel blender comprises:

a feeder coupling the pre-gel storage unit to a first input of a mixer;

a fourth pump coupled to a second input of the mixer;

wherein the pre-gel storage unit contains a solid component of a well treatment fluid;

wherein the feeder supplies the solid component of the well treatment fluid to the mixer;

wherein the fourth pump supplies a fluid component of the well treatment fluid to the mixer; and

wherein the mixer outputs a well treatment fluid.

4. The system ofclaim 3, wherein the well treatment fluid is a gelled fracturing fluid.

5. The system ofclaim 4, wherein the solid component is a gel powder.

6. The system ofclaim 4, wherein the fluid component is water.

7. The system ofclaim 3, wherein the central core contains the solid component of the well treatment fluid.

8. The system ofclaim 3, wherein the well treatment fluid is directed to the annular space.

9. The system ofclaim 3, wherein the annular space comprises a tubular hydration loop.

10. The system ofclaim 9, wherein the well treatment fluid is directed from the mixer to the tubular hydration loop.

11. The system ofclaim 3, wherein the well treatment fluid is selected from the group consisting of a fracturing fluid and a sand control fluid.

12. The system ofclaim 3, further comprising a power source to power at least one of the feeder, the mixer and the pump.

13. The system ofclaim 12, wherein the power source is selected from the group consisting of a combustion engine, an electric power supply and a hydraulic power supply.

14. The system ofclaim 13, wherein one of the combustion engine, the electric power supply and the hydraulic power supply is powered by natural gas.

15. The system ofclaim 1, further comprising a load sensor coupled to one of the storage unit, the liquid additive storage module or the pre-gel blender.

16. The system ofclaim 15, further comprising an information handling system communicatively coupled to the load sensor.

17. The system ofclaim 15, wherein the load sensor is a load cell.

18. The system ofclaim 15, wherein a reading of the load sensor is used for quality control.

19. The system ofclaim 1, wherein the electricity is derived from one of a power grid and a natural gas generator set.

20. A modular integrated material blending and storage system comprising:

a first module comprising a storage unit;

a second module comprising a liquid additive storage unit and a first pump for maintaining pressure at an outlet of the liquid additive storage unit; and

a third module comprising a pre-gel blender, wherein the pre-gel blender comprises at least a pre-gel storage unit resting on a leg, further wherein the pre-gel storage unit comprises a central core and an annular space, wherein the annular space hydrates the contents of the pre-gel blender;

wherein an output of each of the first module, the second module and the third module is located above a blender; and

wherein gravity directs the contents of the first module through a hopper, the second module and the third module to the blender;

a second pump;

wherein the second pump directs the output of the blender to a desired down hole location; and

wherein the second pump is powered by one of natural gas and electricity.

21. The system ofclaim 20, wherein each of the first module, the second module and the third module is a self erecting module.

22. The system ofclaim 20, wherein the third module comprises:

a feeder coupling the pre-gel storage unit to a first input of a mixer;

a third pump coupled to a second input of the mixer;

wherein the pre-gel storage unit contains a solid component of a well treatment fluid;

wherein the feeder supplies the solid component of the well treatment fluid to the mixer;

wherein the third pump supplies a fluid component of the well treatment fluid to the mixer; and

wherein the mixer outputs a well treatment fluid.

23. The system ofclaim 22, wherein the well treatment fluid is directed to the blender.

24. The system ofclaim 20, wherein the blender mixes the output of the first module, the second module and the third module.

25. The system ofclaim 20, further comprising a fourth pump for pumping an output of the blender down hole.

26. The system ofclaim 25, wherein the fourth pump is selected from the group consisting of a centrifugal pump, a progressive cavity pump, a gear pump and a peristaltic pump.

27. A method of performing a fracturing operation comprising:

using only electricity produced on-site with conditioned field gas to power one or more pumps for pumping a fracturing fluid down hole during the fracturing operation; and

monitoring and/or controlling one or more aspects of the fracturing operation, wherein the monitoring and/or controlling is powered using the electricity.

28. The method of claim 27, wherein the one or more aspects of the fracturing operation comprises at least one of a weight, mass, and volume of a solid material in a storage unit.

29. The method of claim 27, wherein the monitoring and/or controlling the one or more aspects of the fracturing operation comprises using an electronic load sensor.

30. The method of claim 27, wherein the monitoring and/or controlling the one or more aspects of the fracturing operation comprises using an information handling system to monitor and/or control an amount of material in a storage unit.

31. The method of claim 27, wherein the one or more aspects of the fracturing operation comprises an amount of fluid in a liquid additive storage module.

32. The method of claim 27, wherein the monitoring and/or controlling the one or more aspects of the fracturing operation comprises using an information handling system.

33. The method of claim 27, wherein the monitoring and/or controlling the one or more aspects of the fracturing operation comprises providing a real-time visual depiction of an amount of a solid material in a storage unit.

34. The method of claim 27, wherein the monitoring and/or controlling the one or more aspects of the fracturing operation comprises providing an alert when a solid material in a storage unit reaches a threshold level.

35. The method of claim 27, further comprising using the electricity to power a pre-gel blender and a pre-gel storage unit for hydrating materials used in the fracturing fluid.

36. The method of claim 28, wherein the storage unit is a silo.

37. The method of claim 27, wherein the monitoring and/or controlling the one or more aspects of the fracturing operation comprises using an instrumentality to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data.

38. The method of claim 27, wherein the conditioned field gas is derived from natural gas obtained from a field on which the fracturing operation is being performed.

39. The method of claim 27, wherein the one or more aspects of the fracturing operation comprises at least one of a weight, mass, and volume of a material in a pre-gel storage unit.

40. The method of claim 27, wherein the monitoring and/or controlling one or more aspects of the fracturing operation comprises providing an alert when a material in a pre-gel storage unit reaches a threshold level.

41. The method of claim 27, wherein the monitoring and/or controlling one or more aspects of the fracturing operation comprises providing a real-time visual depiction of an amount of a material in a pre-gel storage unit.

42. A method of performing a fracturing operation comprising:

having an amount of electricity produced on-site with conditioned field gas, wherein the amount of electricity is sufficient to power: (i) a blender for preparing a fracturing fluid, and (ii) one or more pumps for pumping the fracturing fluid down hole during the fracturing operation;

using the blender to prepare the fracturing fluid, wherein the blender is powered using the amount of electricity;

using the one or more pumps to pump the fracturing fluid down hole to perform the fracturing operation, wherein the one or more pumps is powered using the amount of electricity; and

monitoring and/or controlling one or more aspects of the fracturing operation, wherein the monitoring and/or controlling is powered using the amount of electricity.

43. The method of claim 42, wherein the one or more aspects of the fracturing operation comprises at least one of a weight, mass, and volume of a solid material in a storage unit.

44. The method of claim 42, wherein the monitoring and/or controlling the one or more aspects of the fracturing operation comprises using an information handling system.

45. A method of performing a fracturing operation comprising:

using only electricity generated on-site with conditioned field gas to power one or more pumps for pumping the fracturing fluid down hole during the fracturing operation;

having at least one load sensor communicatively coupled to an information handling system;

processing at least one load sensor reading from the at least one load sensor; and

controlling an amount of a solid material used in the fracturing operation based on the at least one load sensor reading, wherein the processing and the controlling are powered using the amount of electricity.

46. The method of claim 45, wherein the controlling the amount of the solid material used in the fracturing operation comprises using a wireless connection.

47. A method of performing fracturing operations comprising:

preparing at least one fracturing fluid at a central work pad;

pumping the at least one fracturing fluid down hole at different well sites to perform the fracturing operations, wherein the pumping comprises using an amount of electricity produced on-site with conditioned field gas, and wherein the amount of electricity is sufficient to power one or more pumps for pumping the at least one fracturing fluid down hole during the fracturing operations; and

monitoring and/or controlling one or more aspects of the fracturing operations using an information handling system.

48. The method of claim 47, wherein the monitoring and/or controlling is powered using the amount of electricity.

49. The method of claim 47, wherein the monitoring and/or controlling the one or more aspects of the fracturing operations using the information handling system comprises:

having at least one load sensor communicatively coupled to the information handling system;

processing at least one load sensor reading from the at least one load sensor; and

controlling an amount of a solid material used in the fracturing operations based on the at least one load sensor reading.

50. The method of claim 49, wherein the processing at least one load sensor reading and/or the controlling the amount of a solid material used in the fracturing operations are powered using the amount of electricity.

51. A method of performing a fracturing operation comprising:

having an amount of electricity produced using conditioned field gas derived from natural gas obtained from a field on which the fracturing operation is being performed, wherein the amount of electricity is sufficient to power one or more pumps for pumping a fracturing fluid down hole during the fracturing operation;

using a blender to prepare the fracturing fluid;

using the one or more pumps to pump the fracturing fluid down hole to perform the fracturing operation, wherein the one or more pumps is powered using the amount of electricity; and

using an information handling system to monitor and/or control one or more aspects of the fracturing operation.

52. The method of claim 51, wherein the one or more aspects of the fracturing operation comprises at least one of a weight, mass, and volume of a solid material in a storage unit.

53. The method of claim 51, wherein the blender is powered using the amount of electricity.

54. The method of claim 51, wherein the information handling system is powered using the amount of electricity.

55. A method of performing a fracturing operation comprising:

using only electricity generated on-site with conditioned field gas to power one or more pumps for pumping the fracturing fluid down hole during the fracturing operation;

having at least one load sensor communicatively coupled to an information handling system;

processing at least one load sensor reading from the at least one load sensor; and

controlling an amount of a solid material used in the fracturing operation based on the at least one load sensor reading.

56. The method of claim 55, wherein the controlling the amount of the solid material used in the fracturing operation comprises using a wireless connection.

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