EP2981669A1 - Systèmes de fracturation et procédés pour un puits de forage - Google Patents

Systèmes de fracturation et procédés pour un puits de forage

Info

Publication number
EP2981669A1
EP2981669A1 EP14759998.9A EP14759998A EP2981669A1 EP 2981669 A1 EP2981669 A1 EP 2981669A1 EP 14759998 A EP14759998 A EP 14759998A EP 2981669 A1 EP2981669 A1 EP 2981669A1
Authority
EP
European Patent Office
Prior art keywords
proppant
medium
formation
providing
combinations
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP14759998.9A
Other languages
German (de)
English (en)
Other versions
EP2981669A4 (fr
Inventor
Robert Lestz
John THRASH
Audis Byrd
Jim JUNKINS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Prostim Labs LLC
Original Assignee
Prostim Labs LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Prostim Labs LLC filed Critical Prostim Labs LLC
Priority to EP18198030.1A priority Critical patent/EP3447238A1/fr
Publication of EP2981669A1 publication Critical patent/EP2981669A1/fr
Publication of EP2981669A4 publication Critical patent/EP2981669A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/25—Methods for stimulating production
    • E21B43/26—Methods for stimulating production by forming crevices or fractures
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/25—Methods for stimulating production
    • E21B43/26—Methods for stimulating production by forming crevices or fractures
    • E21B43/267—Methods for stimulating production by forming crevices or fractures reinforcing fractures by propping
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/60—Compositions for stimulating production by acting on the underground formation
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/25—Methods for stimulating production
    • E21B43/26—Methods for stimulating production by forming crevices or fractures
    • E21B43/2607—Surface equipment specially adapted for fracturing operations
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K2208/00—Aspects relating to compositions of drilling or well treatment fluids
    • C09K2208/10—Nanoparticle-containing well treatment fluids

Definitions

  • Embodiments usable within the scope of the present disclosure relate, generally, to systems, methods, devices, and compositions usable within a wellbore, and more specifically, to systems and methods for fracturing a subterranean formation to stimulate production (e.g., of hydrocarbons) therefrom.
  • fracturing To stimulate and/or increase the production of hydrocarbons from a well, a process known as fracturing (colloquially referred to as "fracing") is performed.
  • fracturing a process known as fracturing
  • a pressurized fluid - often water - is pumped into a producing region of a formation at a pressure sufficient to create fractures in the formation, thereby enabling hydrocarbons to flow from the formation with less impedance.
  • Solid matter such as sand, ceramic beads, and/or similar particulate-type materials, can be mixed with the fracturing fluid, this material generally remaining within the fractures after the fractures are formed.
  • the solid material serves to prevent the fractures from closing and/or significantly reducing in size following the fracturing operation, e.g., by "propping" the fractures in an open position
  • proppant serves to prevent the fractures from closing and/or significantly reducing in size following the fracturing operation, e.g., by "propping" the fractures in an open position
  • the presence of open, propped fractures provides a beneficial contrast between the permeability in the fracture versus that in the adjacent subterranean reservoir. This contrast provides for a highly conductive pathway for reservoir fluids to travel, thus enhancing the productivity of the well.
  • aqueous fracturing fluid recovered from a well contains various wellbore fluids and other chemicals (e.g., additives to facilitate fracturing using the fluid), and as such, the recovered fracturing fluid must be collected and stored at the surface and disposed of in an environmentally acceptable manner, as required by numerous regulations.
  • Such a process can add considerable time and expense to a fracturing operation, especially when considering the enormous quantities of liquid required to perform the operation.
  • Non-aqueous fracturing fluids have been used as an alternative, one such successful class including hydrocarbon-based fluids (e.g., crude/refined oils, methanol, diesel, condensate, liquid petroleum glass (LPG) and/or other aliphatic or aromatic compounds).
  • hydrocarbon-based fracturing fluids are inherently compatible with most reservoir formations, being generally non-damaging to formations while creating acceptable fracture geometry.
  • enhanced safety preparations and equipment are necessary when using such fluids for wellbore operations.
  • many hydrocarbon-based fluids are volatile and/or otherwise unsuitable for use at wellbore temperatures and pressures, while lacking the density sufficient to carry many types of proppant.
  • a fracturing operation typically requires use of one or more high pressure pumps to pressurize the fracturing fluid that is pumped into a wellbore, as well as to transport fluid and/or proppant toward the wellbore.
  • the passage of proppant through a pump can damage the pump, especially in the absence of a significant quantity of liquid in the slurry.
  • pumps and other such equipment are conventionally driven/powered using diesel engines, which can be responsible for significant quantities of noise, emissions, maintenance, and expense at a worksite, and which require the handling of volatile fluids to fuel and operate.
  • Electric drive systems have been contemplated as an alternative to diesel engines; however, such systems require numerous pieces of equipment, extensive cabling and/or similar conduits, and typically utilize on-site power generation, such as a natural gas turbine.
  • Use of turbine prime movers and similar equipment may be unsuitable when utilizing fracturing fluids that include flammable components.
  • An exemplary electrically powered system for use in fracturing underground formations is described in published United States Patent Application 2012/0255734, which is incorporated by reference herein in its entirety.
  • Embodiments usable within the scope of the present disclosure include systems and methods usable for stimulating a formation (e.g., by forming fractures therein), by providing a first medium to the formation via a first supply subsystem, and a pressure subsystem comprising a pump usable to pressurize the first medium to a pressure sufficient to stimulate the formation.
  • first medium is used herein to refer, generally, to any type of solid, liquid, or gas able to be flowed, e.g., through a conduit, from a source toward a formation, such through use of one or more pumps or other sources of motive force to move the medium and/or pressurize the medium for performance of a fracturing operation.
  • the first medium can include a liquid alkane, and in more specific embodiments, a non-gelled liquid alkane.
  • a non-gelled liquid alkane is used, herein to refer to a medium lacking conventional gellants and/or gelling agents.
  • a non-gelled liquid alkane can be used in a chemical-free (e.g., pure) form, it should be understood that if desired, surfactants and/or other types of viscosity modification can be used to modify the first medium without departing from the scope of the present disclosure.
  • the non-gelled liquid alkane can include an alkane having from one to six carbon atoms (e.g., propane and/or a mixture of other low molecular weight alkanes).
  • the first medium can include a halogenated hydrocarbon.
  • halogenated hydrocarbons are significantly less flammable or in many cases, non-flammable.
  • exemplary halogenated hydrocarbons usable within the scope of the present disclosure can include, without limitation, 1,1,1,3,3,3 hexafluoropropane; 1,1,1,2,3,3,3 heptafluoropropane; 1-methoxyheptafluoro propane; 2,3,3,3-tetraflurorpropene; 1,3,3,3-tetrafluoropropene; 1,1,1, 2,2,3,4,5, 5,5-decafluoro-3-methoxy-4- trifluoromethyl-pentane; l,l,l,4,4,4-hexafluoro-2-butene- 1-methoxy; 1,1,1,2- tetrafluoroethane; or combinations thereof.
  • the first medium can include a halogenated alkene, a halogenated ether, a halogenated olefin, or combinations thereof.
  • the halogenated hydrocarbon can constitute all or a portion of the first medium.
  • the first medium can include a non-halo genated hydrocarbon mixed with the halogenated hydrocarbon (e.g., typically 5% or less of the non-halo genated hydrocarbon by volume, though other concentrations can be used without departing from the scope of the present disclosure), such that although the first medium contains flammable components, the halogenated hydrocarbon reduces the overall flammability of the first medium.
  • the first medium can include a foamed hydrocarbon (e.g., an alkane or another type of hydrocarbon, including, without limitation, liquefied natural gas, diesel and/or any other hydrocarbon-based fluid).
  • a foamed hydrocarbon can include any type of hydrocarbon usable, e.g., as a fracturing fluid, mixed with a quantity of inert gas sufficient to "foam" the hydrocarbon (e.g., from 45% to 90% inert gas by volume).
  • the hydrocarbon can be mixed with a fluoro surfactant to promote foaming of the first medium.
  • the first medium can include propylene carbonate, e.g., as a more dense and/or environmentally friendly alternative to many other hydrocarbon-based fluids.
  • propylene carbonate e.g., as a more dense and/or environmentally friendly alternative to many other hydrocarbon-based fluids.
  • One or more water-soluble polymers such as hydroxylpropyl cellulse ether or a similar non-ionic cellulose either, can be used to alter the viscosity and/or other characteristics of the propylene carbonate.
  • gas e.g., nitrogen and/or carbon dioxide
  • sufficient gas can be provided to energize the first medium (e.g., up to 45% gas by volume), to foam the first medium (e.g., 45% to 90% gas by volume), or to mist the first medium (e.g., greater than 90% gas by volume).
  • the first medium may not include a "fluid" in the conventional sense.
  • a fluidized solid proppant e.g., a solid material adapted to follow, substantially free of liquid, in the manner of a liquid when flowed at a threshold pressure and/or velocity, while behaving in the manner of a solid at pressures and/or velocities less than the threshold.
  • solid particulate matter such as sand, ceramic, glass, clay, gravel, and/or other similar solid particles, can be mixed with a friction- reducing additive, such that the particles of solid matter can flow relative to one another.
  • usable friction-reducing additives could include molybdenum disulfide, carbon black, graphite, fumed silica, epoxy matrix resin nanoparticles, glass bubbles, or combinations thereof.
  • the friction- reducing additive can coat and/or otherwise be interspersed between particles of solid matter, such that the solid matter can pass and/or flow relative to one another with reduced friction, e.g., behaving in a manner similar to a liquid once sufficient pressure and/or velocity is imparted thereto.
  • a fluidized solid proppant could include a material capable of flowing in the manner of a liquid at a threshold pressure and/or velocity in the absence of an additive (such as a friction-reducing component).
  • an additive such as a friction-reducing component
  • glass bubbles and/or microspheres could be used as a fluidized solid proppant independent of or in addition to a friction-reducing additive.
  • one or more solid components adapted to flow in the manner of a liquid when vibrated or pulsed could be used; for example, sand and/or similar particulate matter can be flowed toward a formation if vibrated and/or pulsed at a suitable frequency.
  • a pneumatic conveying system can be used to vibrate and/or pulse the particulate matter to facilitate movement thereof.
  • a quantity of liquid e.g., a lubricant, a fracturing fluid, etc.
  • a quantity insufficient to form a slurry with the proppant can be used due to the fact that the proppant, itself, can be flowed toward the formation without slurrying the proppant.
  • the first medium can include a liquid material adapted to solidify at a threshold temperature (e.g., a foam material), such that the medium can be flowed into the formation as a liquid, then solidified (e.g., into a porous, solid material) after reaching fractures in the formation, enabling the solidified material to function as proppant.
  • a threshold temperature e.g., a foam material
  • a cooling fluid could be injected to prepare the formation to receive the liquid material without premature solidification thereof.
  • the supply subsystem used to store and/or flow the first medium toward the formation can include one or more vessels adapted for containment thereof and/or for driving the first medium.
  • a vessel can be supplied with an inert gas (e.g., nitrogen or another similar gas) above and/or otherwise in association with the first medium, such that pressure of the inert gas can be used to drive the first medium from the vessel toward the formation.
  • an inert gas e.g., nitrogen or another similar gas
  • a separator such as a bladder, a piston and/or another similar member
  • a pressurized fluid to move the separator.
  • a vertically oriented vessel can be used, such that gravity and/or vapor pressure of the first medium can drive the first medium from the vessel toward the formation.
  • a booster pump associated with the vessel can be used to draw the first medium from therein and feed the first medium to an additional pump (e.g., a pump used to mix the first medium with a proppant, to transport the first medium to high pressure fracturing pumps, and/or to pressurize the first medium).
  • an additional pump e.g., a pump used to mix the first medium with a proppant, to transport the first medium to high pressure fracturing pumps, and/or to pressurize the first medium.
  • Use of a separate booster pump can prevent the vaporization of volatile components (e.g., low molecular weight alkanes) caused by the intake thereof at one or more of the additional pumps.
  • the vertically oriented vessel can be adapted for transport in a horizontal orientation (e.g., on a truck, trailer, and/or similar vehicle or mode of transport).
  • a vessel can include a plurality of outlets, the size and number thereof selected to flow the first medium from the vessel toward the formation at a rate sufficient to perform a desired operation (e.g., a stimulation and/or fracturing operation).
  • a pipeline in communication with a remote source can be used to supply the first medium to the formation directly, in addition to or in lieu of one or more on-site storage vessels.
  • the systems and methods described herein can be used for stimulation and/or fracturing operations.
  • the first medium can include a fracturing fluid (e.g., water, hydrocarbons, and/or any of the fluids and/or media described previously).
  • a second supply subsystem can be used to provide a second medium that includes a proppant (potentially with lubricants and/or other additives) to the formation.
  • the fracturing fluid can include a non-gelled liquid alkane, as described above, and the proppant can include a specific gravity, a size (e.g., a diameter) or combinations thereof adapted to provide the proppant with a substantially neutral or positive buoyancy in the fracturing fluid.
  • substantially neutral buoyancy can include a neutral, positive, or negative buoyancy in which the proppant does not settle at a rate sufficient to prevent use of the fracturing fluid and proppant in a fracturing operation.
  • the proppant can have a specific gravity of 1.5 or less, and in a further embodiment, the proppant can have a specific gravity of 1.1 or less.
  • proppant particles could have a diameter of 105 microns or less to facilitate buoyancy thereof.
  • the proppant can include a hollow material, such as glass bubbles, cenospheres, microspheres, and/or other similar materials having a structure sufficient to function as proppant while remaining generally buoyant in a fracturing fluid.
  • the proppant can include a composite material, such as a syntactic foam.
  • the proppant can include a porous material, such as an aerogel, a resin-coated aerogel, a resin-coated pumice, a ceramic foam or other type of foamed material, or combinations thereof.
  • a "porous material" can include particles having cylindrical and/or tubular structures (e.g., having an axial bore) through which fluid can pass.
  • the proppant can include a porous material that is permeable to reservoir fluids, such as a filter material that permits passage of the fluid into and through particles of proppant, while the structure of the material enables the material to function as proppant.
  • the proppant material can include a crystalline material, such as zircon or other similar crystalline materials.
  • a friction-reducing additive such as those described above, can be combined with proppant particles to facilitate transport of the proppant, e.g., from a vessel or similar source into the fluid path of the fracturing fluid and/or a vessel containing fracturing fluid, such that the proppant can be flowed into communication with the fracturing fluid in the absence of a sufficient quantity of liquid to slurry the proppant.
  • the second supply subsystem can include one or move vessels used to store and/or drive the proppant toward the formation.
  • a vertically oriented vessel can be used to enable gravity, the weight of the proppant, or combinations thereof to drive the proppant from the vessel toward the formation.
  • a positive displacement pump, a centrifugal pump, other similar sources of motive force can be used to move proppant toward the formation.
  • a positive displacement pump for example, could be positioned in a non-horizontal orientation to facilitate intake of proppant (e.g., assisted by gravity).
  • an inert gas e.g., nitrogen or a similar gas
  • a pressure thereof can be used to drive the proppant from the vessel toward the formation.
  • a separator e.g., a piston, a bladder, and/or another similar device
  • a pneumatic conveying system can be used to drive proppant toward the formation (e.g., by pushing proppant within the vessel and/or pulling proppant from the vessel).
  • a venturi nozzle can be positioned in communication with a flowpath of the fracturing fluid to reduce a pressure thereof. In doing so, proppant from the second supply subsystem can be drawn into the flowpath of the fracturing fluid.
  • the venturi nozzle can include an elastomeric nozzle adapted to adjust (e.g., self-adjust) to provide a substantially constant pressure drop across the nozzle independent of the flow rate and/or conditions of the fracturing fluid and/or the proppant.
  • the pressure subsystem can include an electric -powered driver (e.g., an electric motor or similar source of force) in communication with and actuating the pump, while an electrical power source powers the electric-powered driver.
  • an electric -powered driver e.g., an electric motor or similar source of force
  • an electrical power source powers the electric-powered driver.
  • a turbine generator e.g., a natural gas turbine or similar source
  • a grid-based power source can be used to power the electric-powered driver.
  • an electric-powered driver can be configured for selective and/or simultaneous operation using a grid-based or an on-site power source. Where a grid-based power sourced is used, in an embodiment, one or more additional transformers can be used to convert power from the grid-based power source to a desired voltage.
  • a single pump can be actuated using a single electric -powered driver or multiple electric-powered drivers, and multiple pumps can be actuated using a single electric-powered driver or multiple electric-powered drivers.
  • a single power source can power one or multiple electric-powered drivers, or one or multiple electric- powered drivers can be powered by multiple power sources.
  • a transformer can be used to alter power from the electrical power source from a first voltage to a second voltage suitable for powering the electric-powered driver.
  • a pump, an electric -powered driver, and a transformer can be positioned on a mobile vehicle.
  • a variable frequency drive can also be included, e.g., on the mobile vehicle, in communication with the transformer and the electric -powered driver. While the above embodiment describes a single pump, electric -powered driver, transformer, and variable frequency drive situated on a mobile vehicle, it should be understood that one or multiple of each type of component described above and/or other components could be included on a vehicle without departing from the scope of the present disclosure. Other configurations of mobile vehicles can also be used without departing from the scope of the present disclosure.
  • a transformer, a variable frequency drive, an electric motor or other type of driver, and a pump can be situated on a single mobile vehicle.
  • a transformer and variable frequency drive can be positioned on a first mobile vehicle, while one or multiple additional vehicles, each containing one or a plurality of motors and one or a plurality of pumps, can be placed in communication with the variable frequency drive.
  • a transformer and one or multiple variable frequency drives can be positioned remote from a mobile vehicle (e.g., outside of an operational zone), while conduits can engage each variable frequency drive with one or multiple mobile vehicles, each vehicle containing one or multiple electric-powered drivers and pumps.
  • the arrangement of components can be selected such that the electrical power source can engage the transformer, and thereby, the electric- powered driver, via a single electrical conduit.
  • an electrical power source can be engaged with a transformer (and subsequently, to other associated components) via a single electric conduit, eliminating much of the cabling/conduits present at conventional worksites.
  • transformers can be used, as needed, to alter the voltage of power received from one or more sources to voltages suitable for use with various system components
  • the system components can be adapted for use with low or medium voltages.
  • use of air moving devices may be incorporated to control the concentration of vapors (e.g., hydrocarbon-based gasses and/or similar components) proximate to pumps and/or other system components.
  • vapors e.g., hydrocarbon-based gasses and/or similar components
  • propane as a fracturing fluid
  • the accumulation of propane proximate to the pump could create a flammable condition (e.g., at a propane concentration of approximately 2.2% to 9.5% in air), while the continuous movement of air proximate to the pump would prevent accumulation of flammable components at a concentration sufficient for ignition.
  • an electric motor or similar electric-powered driver can include a fan, blower, or other type of air moving device associated therewith, and placement of the driver and/or air moving device can be selected such that the air moving device flows air proximate to the pump for dispersing gas therefrom.
  • an enclosed conduit can extend between the electric-powered driver and the pump, such that air form the air moving device flows from the driver to the pump via the conduit.
  • an electric powered driver and pump can be enclosed within a single housing, such that air from the air moving device flows proximate to the pump.
  • a drive shaft extending between the electric -powered driver and the pump can have protrusions (e.g., blades, fins, etc.) extending therefrom, such that as the air moving device flows air into contact with the protrusions, motive force is provided to the drive shaft.
  • protrusions e.g., blades, fins, etc.
  • movement of the drive shaft can, itself, be used to flow air (e.g., via the protrusions) to circulate air proximate to the pump, in addition to or in lieu of an air-moving device associated with the electric-powered driver.
  • Figure 1 depicts a diagram of an embodiment of a system usable within the scope of the present disclosure.
  • Figure 2A depicts a diagrammatic side view of an embodiment of a motor engaged with a pump, usable within the scope of the present disclosure.
  • Figure 2B depicts a diagrammatic side view of an embodiment of a motor engaged with a pump, usable within the scope of the present disclosure.
  • Figure 2C depicts a diagrammatic side view of an embodiment of a motor engaged with a pump, usable within the scope of the present disclosure.
  • Figure 3 depicts a diagrammatic side view of an embodiment of a motor engaged with a pump, usable within the scope of the present disclosure.
  • Figure 4 depicts a diagrammatic side view of an embodiment of a motor engaged with a pump, usable within the scope of the present disclosure.
  • Figure 5 depicts a diagrammatic side view of an embodiment of a variable frequency drive usable within the scope of the present disclosure.
  • Figure 6A depicts a diagram of an embodiment of a power and pumping subsystem usable within the scope of the present disclosure.
  • Figure 6B depicts a diagram of an embodiment of a power and pumping subsystem usable within the scope of the present disclosure.
  • Figure 6C depicts a diagram of an embodiment of a power and pumping subsystem usable within the scope of the present disclosure.
  • Figure 7 depicts an embodiment of a system usable within the scope of the present disclosure.
  • Figures 8A through 8D depict diagrams of a wellbore, illustrating an embodiment of a proppant medium usable within the scope of the present disclosure
  • Figure 9A depicts a diagrammatic embodiment of a proppant medium usable within the scope of the present disclosure.
  • Figure 9B depicts a diagrammatic embodiment of a proppant medium usable within the scope of the present disclosure.
  • Figure 1 depicts an embodiment of a system usable to inject a fluid under pressure into a well (10).
  • the depicted system can be used to stimulate production (e.g., of hydrocarbons) by forming fractures in the wellbore formation through the provision of a pressurized fracturing fluid into the well (10), mixed with proppant (e.g., solid particulate matter) to maintain and/or support the fractures while permitting the flow of hydrocarbons or other fluids from the formation into the wellbore and toward the surface.
  • production e.g., of hydrocarbons
  • proppant e.g., solid particulate matter
  • Figure 1 subdivides the depicted system into a first subsystem— a fluid addition subsystem (12) for providing fracturing fluid or a similar medium to the well (10), a second subsystem— a proppant addition subsystem (14) for providing proppant or a similar medium into the fracturing fluid, a power subsystem (16) for providing power to one or more components of the system, and a pumping subsystem (17) for pressurizing fluid for injection into the well (10).
  • a first subsystem a fluid addition subsystem (12) for providing fracturing fluid or a similar medium to the well (10)
  • a second subsystem— a proppant addition subsystem (14) for providing proppant or a similar medium into the fracturing fluid
  • a power subsystem (16) for providing power to one or more components of the system
  • a pumping subsystem (17) for pressurizing fluid for injection into the well (10).
  • any number, type, and arrangement of identical or similar components could be used without departing from the scope of the present disclosure.
  • the fluid addition subsystem (12) could be used in the absence of the other subsystems (14, 16, 17) and/or in combination with conventional systems and/or components.
  • the proppant addition subsystem (14) and the pumping and power subsystems (16, 17) could be used independently or in combination with conventional systems and/or components without departing from the scope of the present disclosure.
  • the depicted fluid addition subsystem (12) includes a plurality of tanks (18A,
  • fracturing fluids While gelled liquid petroleum gas has been used in fracturing fluids to minimize damage to formations, driven by pressure applied using inert gas (e.g., nitrogen), as described in U.S. Patent 8,408,289, incorporated by reference above, embodiments usable within the scope of the present disclosure can include use of liquid propane and/or other alkanes, without the addition of gellants or other chemical additives. Additionally, to reduce or eliminate the flammability of the hydrocarbon-based fracturing fluid, in an embodiment, a halogenated hydrocarbon can be present, alone or in combination with non-halogenated hydrocarbons.
  • inert gas e.g., nitrogen
  • 1,1,1, 2,3, 3,3-Heptafluoropropane or a similar halogenated hydrocarbon compound composed of an aliphatic or aliphatic derivative (e.g., ethers and/or olefins) with one or more halogen elements (e.g., fluorine, bromine, etc.) could be present in the fracturing fluid, such that the resulting fluid is fire retardant or non-flammable.
  • a portion of the fracturing fluid could include a halogenated compound while still providing the fracturing fluid with fire retardant and/or non-flammable properties, though any quantity of halogenated compounds could be used without departing from the scope of the present disclosure.
  • heptafluoropropane is referenced as an individual exemplary embodiment; hydrofluoroalkenens, hydrofluoroethers, and other types of halogenated compounds can also be used without departing from the scope of the present disclosure.
  • use of halongenated hydrocarbons can provide additional beneficial properties beyond non-flammability, due in part to the higher fluid density and viscosity of the halogenated compounds compared to non-halogenated hydrocarbons.
  • Exemplary halogenated hydrocarbons usable within the scope of the present disclosure can include, without limitation: 1,1,1,3,3,3 hexafluoropropane; 1,1,1,2,3,3,3 heptafluoropropane; 1-methoxyheptafluoro propane; 2,3,3,3-tetraflurorpropene; 1,3,3,3-tetrafluoropropene; 1,1,1, 2,2,3,4,5, 5,5-decafluoro-3-methoxy-4- trifluoromethyl-pentane; 1,1,1 ,4,4-hexafluoro-2-butene; 1 -methoxy- 1,1,1,2- tetrafluoroethane; or combinations thereof.
  • the fracturing fluid can include propylene carbonate, e.g., as an "environmentally friendly" fluid, having a density greater than other hydrocarbon fluids (e.g., a specific gravity of approximately 1.2), which can reduce hydrostatic head pressure and surface treating pressure of the fluid, resulting in lower horsepower requirements to pump the fluid.
  • propylene carbonate can be produced with recovered hydrocarbons, eliminating the need for any post-handling, processing, disposal, and/or separation operations to recover the propylene carbonate.
  • propylene carbonate enables water- soluble polymers to be used in lieu of conventional additives and viscosifiers, one such water-soluble polymer including non-ionic cellulose ethers, such as hydroxylpropyl cellulose ether (sold under the trade name Klucel).
  • a gas e.g., nitrogen or carbon dioxide
  • up to 45% gas by volume could be provided to energize the fracturing fluid, from 45% to 90% by volume could be provided to foam the fluid, and from 90% to less than 100% by volume could be provided to mist the fluid, allowing the density of the propylene carbonate to be altered as needed (e.g., depending on formation conditions), reducing the hydrostatic head pressure of the fluid.
  • propylene carbonate can be mixed with other liquids or gasses, e.g., at the surface or as it is being moved toward the formation, e.g., to change the density and/or viscosity thereof, to enhance proppant transport characteristics (e.g., by foaming, emulsifying, and/or gelling the propylene carbonate), to reduce conduit friction pressure, to help control fluid loss, and to increase fluid efficacy during fracturing operations.
  • other liquids or gasses e.g., at the surface or as it is being moved toward the formation, e.g., to change the density and/or viscosity thereof, to enhance proppant transport characteristics (e.g., by foaming, emulsifying, and/or gelling the propylene carbonate), to reduce conduit friction pressure, to help control fluid loss, and to increase fluid efficacy during fracturing operations.
  • the fracturing fluid can include a foamed hydrocarbon
  • a hydrocarbon can be stored in the tanks (18A, 18B, 18C), and/or a gas source (not shown) (e.g., a pressurized gas source and pump) can be configured to inject and/or mix gas into the flowpath of fluid from the tanks (18A, 18B, 18C) (e.g., downstream from the tanks), and/or into an intermediate vessel where fluid from the tanks (18A, 18B, 18C) can be mixed with the gas.
  • a fluorosurfactant can be provided in the tanks (18A, 18B, 18C), in the gas, and/or from a separate source to facilitate stabilization of the foamed hydrocarbon.
  • the fracturing fluid can include a fluidized solid proppant material, as described above.
  • Fluidized solid proppant can include solid particulate matter (e.g., sand, ceramic, glass, clay, gravel, etc.), mixed with a solid or liquid friction-reducing additive (e.g., molybdenum disulfide, carbon black, graphite, fumed silica, epoxy matrix resin nanoparticles, glass bubbles, and/or silicone lubricants), to enable the solid material to flow in the manner of a liquid under sufficient pressure to impart movement thereto, while behaving in the manner of a solid in the absence of such pressure.
  • a solid or liquid friction-reducing additive e.g., molybdenum disulfide, carbon black, graphite, fumed silica, epoxy matrix resin nanoparticles, glass bubbles, and/or silicone lubricants
  • a fluidized solid proppant can be flowed, substantially in the absence of liquid (e.g., a quantity of liquid insufficient to form a slurry therewith), into a wellbore for performance of a fracturing operation, then permitted to settle and/or remain within the fractures via a cessation of pressure applied from the surface.
  • the fluidized solid proppant can include solid material (e.g., sand or similar particulate matter) that can flow in the manner of a liquid when vibrated and/or pulsed (e.g., using a pneumatic conveyance system to pulse air and/or other fluids through the proppant), with or without the addition of a friction-reducing additive.
  • fluidized solid proppant can include materials that flow in the manner of a liquid under a threshold pressure in the absence of a friction- reducing additive.
  • a friction-reducing additive for example, "glass bubbles,” available from 3M of St. Paul, Minnesota, or similar microspheres or other types of particulate matter having a size, shape, surface feature, and/or other characteristic that reduces or inhibits frictional interactions with adjacent particles.
  • the tanks (18A, 18B, 18C) can contain a liquid adapted to solidify under threshold conditions (e.g., temperature), such that the liquid can be flowed into the well (10) until it reaches a fracturing zone, then allowed to solidify within fractures.
  • threshold conditions e.g., temperature
  • binary addition of multiple components could be used.
  • the well (10) can be pre-treated using a fluid to at least temporarily cool the formation prior to flowing the liquid into the well (10), such that the material does not solidify prematurely.
  • FIG. 1 depicts the tanks (18A, 18B, 18C) as generally cylindrical vessels having a vertical orientation.
  • Use of vertically-oriented tanks to contain propane and/or other alkanes (and/or halogenated hydrocarbons) can enable gravity and/or vapor pressure above the contents of the tanks to aid in driving the contents toward the well (10), thus requiring lower energy and/or lower power pumping equipment, while also enabling the tanks to include a smaller quantity of unused volume (e.g., "tank bottoms”) when compared to a horizontally-oriented tank.
  • Vertical tanks also provide a smaller footprint than horizontal tanks and other alternatives.
  • any type of vessel usable to contain fracturing fluid can be used without departing from the scope of the present disclosure.
  • the tanks (18A, 18B, 18C) can include multiple outlets to facilitate flowing of fluid therefrom at a rate sufficient to perform fracturing or other operations.
  • the tanks (18A, 18B, 18C) can be portable/transportable (e.g. skid-mounted or otherwise structured to facilitate transportability) in a generally horizontal orientation prior to erecting the tanks in a vertical orientation.
  • use of on- site vessels containing fracturing fluid could be omitted, and pipelines or similar conduits from a remote source could be used to continuously or intermittently supply fracturing fluid to the well (10).
  • the tanks (18A, 18B, 18C) are shown in communication with a fluid source (20) for supplying a first medium (e.g., propane, alkanes, and/or other types of fracturing fluid) thereto via a fill line (22).
  • a vent line (24) is also usable, e.g., to relieve pressure from the tanks (18A, 18B, 18C) and/or otherwise facilitate flow thereto and therefrom.
  • Each tank (18A, 18B, 18C) is shown in communication with an associated pump (26A, 26B, 26C) (e.g., a booster pump), usable to draw fracturing fluid therefrom and flow the fluid toward the well (10) via a conduit (28).
  • a secondary fluid booster pump (30) is shown for further driving the fluid toward the well (10), through a low pressure region (32) of the conduit. While Figure 1 depicts each tank (18A, 18B, 18C) having a respective associated pump (26A, 26B, 26C) associated therewith, and a secondary booster pump (30) to further drive the fluid, it should be understood that in various embodiments, a secondary pump may be omitted, a single pump could be used to draw fluid from multiple tanks, multiple pumps could be used to draw fluid from a single tank, or use of pumps could be omitted. In an embodiment, gravity, vapor pressure, and/or pressure applied to the tanks (18A, 18B, 18C) and/or the contents thereof using external sources could be used to drive fracturing fluid toward the well (10) in lieu of pumps.
  • nitrogen and/or another type of inert gas could be provided in the tanks (18A, 18B, 18C) with the first medium and the pressure thereof could be altered and/or otherwise used to facilitate driving of the fracturing fluid toward the well (10).
  • a bladder, piston, and/or similar type of separator can be provided in the tanks and driven (e.g., using a pressurized fluid, hydraulic and/or pneumatic mechanisms, mechanical force, other similar means, or combinations thereof) to drive the contents of the tanks (18A, 18B, 18C) toward the well (10).
  • the depicted proppant addition subsystem (14) includes a plurality of proppant storage vessels (34A, 34B, 34C) (e.g., silos or another type of tank and/or container), positioned in association with a conveyor (36), which can include one or more conveyor belts, chutes, slides, pipes, or other types of conduits and/or means of conveyance usable to transport proppant from the vessels (34A, 34B, 34C) toward a hopper (38) or similar type of container.
  • a conveyor which can include one or more conveyor belts, chutes, slides, pipes, or other types of conduits and/or means of conveyance usable to transport proppant from the vessels (34A, 34B, 34C) toward a hopper (38) or similar type of container.
  • Use of vertically oriented proppant storage vessels, such as silos can enable gravity and/or the weight of the proppant to drive proppant from the containers toward the conveyor (36) and/or toward the well (10), while also reducing the footprint presented by the
  • One exemplary proppant storage container could include a Model 424 Sand Silo, produced by Loadcraft Industries, LTD of Brady, Texas, which can include an associated transportation trailer.
  • Proppant within the vessels can include any manner of small and/or particulate solid matter usable to retain and/or support fractures in a formation, such as sand, glass or clay beads, gravel, or other similar types of material and or particulate matter, such as crystalline material (e.g., zircon) and/or hollow glass particles (e.g., glass bubbles/microspheres, such as those made by 3M of St. Paul, Minnesota), among other possible alternatives.
  • the proppant can have characteristics selected to facilitate buoyancy and/or transport within the fluid.
  • the proppant can be provided with a specific gravity of less than 1.5 and in an embodiment, less than 1.1, to facilitate transport in propane and/or other non-gelled alkanes, propylene carbonate, and/or other similar types of fracturing fluids.
  • the proppant can be provided with a size sufficiently small to promote transport, such as particles having a diameter of 105 micros or less.
  • the proppant can include hollow materials (e.g., glass bubbles, cenospheres, and/or microspheres).
  • the proppant can include a composite material, such as a syntactic foam.
  • the proppant can include a porous material, such as an aerogel, a resin-coated aerogel, a pumice, a resin-coated pumice, a ceramic foam or other foamed material, and/or a tubular- shaped (e.g., cylindrical) material having an axial bore through which fluid can flow.
  • the proppant can include a crystalline material, such as zircon.
  • Figure 1 depicts three proppant storage vessels (34A, 34B, 34C) in association with a conveyor (36) for transporting the proppant to a hopper (38) or other type of second container
  • a single hopper or container could be used, while omitting separate storage containers and a conveyor, or use of a hopper or other type of secondary container could be omitted while proppant is conveyed toward the well (10) directly from storage containers.
  • the hopper (38) serves as a location where a lubricating fluid from a lubrication source (40) (e.g., a tank) can be provided to dispensed proppant, via a conduit (44) and lubrication pump (42).
  • a lubrication source e.g., a tank
  • Usable lubricating fluids can include fracturing fluid identical or similar to that stored in the tanks (18A, 18B, 18C) of the fluid addition subsystem (12), mineral oil, or any other suitable lubricant that is generally non-damaging to system components and compatible with the fracturing fluid in the tanks (18A, 18B, 18C), and the formation and reservoir fluids in the well (10).
  • usable lubricants can include one or more friction-reducing additives, such as those described above with regard to use of a fluidized solid proppant, for enabling proppant to be flowed from the vessels (34A, 34B, 34C) into the flowstream of the fracturing fluid without requiring formation of a slurry and/or in the absence of a substantial quantity of fluid.
  • friction-reducing additives could be included within and/or directly added to the vessels (34A, 34B, 34C).
  • use of a lubricant may be unnecessary, such as when glass bubbles or a similar type of friction-reduced proppant material is used.
  • any of the proppant materials described herein could be mixed with a friction-reducing additive to allow flowing thereof in the substantial absence of liquid.
  • a proppant pump (45) can be used to drive the proppant and lubricating fluid toward the well (10) and/or to slurry the proppant with the lubricating fluid, if desired and/or necessary.
  • the proppant pump (45) can include a positive displacement pump and/or a centrifugal pump.
  • a positive displacement pump can be provided in a non-horizontal orientation to facilitate intake of proppant from a vertically oriented vessel.
  • the proppant can be mixed with the flowstream of fracturing fluid from the fracturing fluid addition subsystem (12) at an addition point (46) within the low pressure region (32) of the conduit, such that the flow of the proppant and fracturing fluid can mix and/or slurry the proppant and fluid (e.g., due to turbulent flow and/or other factors) to achieve a desired proppant concentration.
  • Generation of a slurry of proppant and fracturing fluid having a generally constant proppant concentration enables the amount of proppant added at the addition point (46) to be controlled solely by modifying the rate of addition of the proppant slurry.
  • a logic system can be used to regulate the flow of proppant based on the flow rate of the fracturing fluid.
  • a venturi nozzle (47) can be positioned in communication with the flowstream of fracturing fluid, e.g., at or near the addition point (46) (e.g., upstream thereof), thereby increasing the velocity and reducing the pressure of fluid at the downstream end of the nozzle (47), such that the flow of lower-pressure fracturing fluid across and/or proximate to the addition point (46) can draw proppant through into the flowstream.
  • a diffuser (49) can be provided downstream from the nozzle (47).
  • An elastomeric (e.g., self-adjusting) nozzle can be used to facilitate a constant pressure drop across the nozzle, thereby facilitating control of the rate/concentration of proppant.
  • Use of a venturi nozzle can further facilitate mixing and/or slurrying of the proppant and fracturing fluid.
  • inert gas can be mixed with the proppant in the vessels (34A, 34B, 34C), the pressure from which can be used to facilitate driving the proppant toward the well (10).
  • a separator such as a piston or bladder, similar to that described above with regard to the tanks (18A, 18B, 18C) can be used to facilitate driving the proppant toward the well (10).
  • fracturing fluid and/or proppant in the low pressure region (32) flows toward the well (10) it is pressurized by one or more high pressure fracturing pumps (70A, 70B, 70C, 70D), defining a high pressure region (72) of the conduit, such that the fluid provided into the well (10) is at a pressure sufficient to generate fractures in the formation.
  • high pressure fracturing pumps 70A, 70B, 70C, 70D
  • the depicted power subsystem (16) is usable to provide power to the high pressure pumps (70A, 70B, 70C, 70D), and/or to other system components (such as the pumps (26A, 26B, 26C, 30, 42, 45) usable to flow fracturing fluid, proppant, and/or lubricating fluid, the proppant conveyor (36), one or more valves associated with system components, and/or other similar elements).
  • the high pressure pumps 70A, 70B, 70C, 70D
  • other system components such as the pumps (26A, 26B, 26C, 30, 42, 45) usable to flow fracturing fluid, proppant, and/or lubricating fluid, the proppant conveyor (36), one or more valves associated with system components, and/or other similar elements).
  • FIG 1 illustrates two methods by which the high pressure pumps (70A, 70B,
  • 70C, 70D and associated components can be powered; however, it should be understood that while the depicted power subsystem (16) includes the simultaneous and/or selective use of two sources of power, in other embodiments, a single source of power could be used. Additionally, while the depicted power subsystem (16) is used to power the high pressure pumps (70A, 70B, 70C, 70D), it should be understood that the power subsystem (16) can be used to power any portion of the depicted system (e.g., the booster pumps associated with the fluid subsystem, the lubrication and slurry pumps associated with the proppant subsystem, proppant conveyors, various associated valves, as well as other fluid systems (not shown) associated with the well (10)).
  • the depicted power subsystem (16) includes the simultaneous and/or selective use of two sources of power, in other embodiments, a single source of power could be used. Additionally, while the depicted power subsystem (16) is used to power the high pressure pumps (70A, 70B, 70C, 70D), it should be
  • the power subsystem (16) is shown having a turbine (52) (e.g., a natural gas turbine or similar type of device usable to produce mechanical output from other forms of energy) coupled with a generator (54), to produce electricity that can be conducted via a cable (56) or similar conduit to other components of the power subsystem (16).
  • a turbine e.g., a natural gas turbine or similar type of device usable to produce mechanical output from other forms of energy
  • a generator e.g., a natural gas turbine or similar type of device usable to produce mechanical output from other forms of energy
  • power can be obtained from an external source (e.g., a municipal power grid, power lines, etc.) (60). While typical electrical power is provided having a voltage of 4,160 volts, in an embodiment, high voltage lines could be used to convey electricity to the system.
  • Figure 1 depicts power lines (60) capable of conveying high voltage, e.g., 13,800 volts or more, to a transformer (62), usable to step down the voltage in the conduit (56) to a typical voltage of 4,160 volts or another usable voltage.
  • Power produced using the generator (54) can be provided at a usable voltage without requiring a transformer; however, a transformer could be used in association with the generator (54) without departing from the scope of the present disclosure.
  • Various embodiments usable within the scope of the present disclosure can include medium voltage and/or low voltage components.
  • Figure 1 depicts four high pressure pumps (70A, 70B, 70C, 70D) usable to pressurize the fracturing fluid.
  • the first and second high pressure pumps (70A, 70B) are shown positioned on a first transport vehicle (48A), which can include, by way of example, a flatbed trailer, a truck, a skid, or any other transportable platform or framework.
  • the third and fourth high pressure pumps (70C, 70D) are shown positioned on a second transport vehicle (48B).
  • Each transport vehicle (48A, 48B) is shown having a transformer (64A, 64B) positioned thereon.
  • a transformer on the vehicle, itself, enables a single respective power cable (58A, 58B) to be extended from the power source to the vehicle (48 A, 48B).
  • a transformer remote from other system components would require numerous cables and/or other conduits extending from the transformer to other system components.
  • positioning of the transformers (64A, 64B) proximate to the high pressure pumps (70A, 70B, 70C, 70D) and other associated components minimizes the distance across which large numbers of cables/conduits must extend.
  • the transformers (64A, 64B) can be adapted to reduce voltage in the cables (58A, 58B) from 4,160 volts to 600 volts, for use by components associated with the high pressure pumps (70A, 70B, 70C, 70D).
  • Figure 1 depicts two variable frequency drives (66A, 66B) in electrical communication with the first transformer (64A), and two variable frequency drives (66C, 66D) in electrical communication with the second transformer (64B).
  • the variable frequency drives (66A, 66B, 66C, 66D) each, in turn, actuate a respective associated electrical motor (68A, 68B, 68C, 68D).
  • Each electrical motor (68A, 68B, 68C, 68D) in turn powers a respective high pressure pump (70A, 70B, 70C, 70D).
  • the electrical motors can include explosion-proof motors, such as ATEX motors, available from TEC Motors of Worcestershire, United Kingdom, among other sources.
  • the transformers (64A, 64B) can be adapted to convert the received power to a larger number of successive electrical phases/pulses.
  • a transformer could receive and convert a three-phase source of power to a nine- phase, eighteen-pulse source of power for transmission to successive system components.
  • the depicted power subsystem (16) is usable to reduce or eliminate conventional use of diesel engines to power high pressure fracturing pumps. Additionally, use of modular sets of components positioned on mobile trailers or similar transportable vehicles (48A, 48B) minimizes the number and length of cables and other conduits required to power each component, while also facilitating installation of each component.
  • all connections between the transformers (64A, 64B), variable frequency drives (66A, 66B, 66C, 66D), motors (68A, 68B, 68C, 68D), and high pressure pumps (70A, 70B, 70C, 70D) can generally be permanently installed, such that the vehicles (48A, 48B) can be positioned at a desired location at an operational site, then engaged with a single cable (58A, 58B), thereby powering each of the components.
  • use of modular, movable sets of components reduces the footprint of the system while enabling flexible positioning of components, as needed, depending on the position of other objects at an operational site.
  • power generation components can be placed remote from other system components, such as the fracturing fluid addition subsystem (12), which reduces risk of ignition when flammable components (e.g., propane) are used in the fracturing fluid.
  • Figure 1 depicts two transportable vehicles (48A, 48B), each having one transformer, two variable frequency drives, two electrical motors, and two high pressure pumps thereon, it should be understood that any number of transportable vehicles can be used, and further, each transportable vehicle could include a single high pressure pump or three or more high pressure pumps without departing from the scope of the present disclosure. Additionally, while Figure 1 depicts a single transformer used in conjunction with two variable frequency drives, two motors, and two high pressure pumps, any number of transformers could be used, or in an embodiment, a suitable voltage could be provided to the components of the power subsystem (16) directly, obviating the need for transformers on the transportable vehicles.
  • Figure 1 depicts a single variable frequency drive used to actuate a single electrical motor, which in turn powers a single high pressure pump
  • a variable frequency drive could actuate multiple motors
  • multiple variable frequency drives could be used to actuate a single motor
  • a single motor could power multiple high pressure pumps
  • multiple motors could power a single high pressure pump.
  • Figures 6A through 6C depict exemplary embodiments of pumping and power subsystems usable within the scope of the present disclosure.
  • Figure 6A depicts a transformer (64) and a variable frequency drive (66) positioned on a first mobile vehicle (49 A), two pumps (70) with associated motors (not shown) positioned on a second mobile vehicle (49B), and two pumps (70) with associated motors (not shown) positioned on a third mobile vehicle (49C).
  • the depicted configuration can utilize a plurality of vehicles (49A, 49B, 49C) to reduce the amount of weight carried by a single vehicle, and is usable for low and/or medium voltage applications (e.g. 600 volts).
  • Figure 6B depicts a configuration in which a transformer (64), variable frequency drive (66), and a pump (70) with an associated motor (not shown) are positioned on a single mobile vehicle (49), which can also be used in low and/or medium voltage applications.
  • FIG. 6C depicts an embodiment in which an operational site has been conceptually divided into a "hazard zone" (5 IB), where potentially dangerous operations can be performed and/or volatile components may accumulate, and a "remote zone" (51 A) that is separated and/or spaced from the hazard zone (5 IB).
  • a transformer (64) and two variable frequency drives (66) are shown positioned in the remote zone (51 A), while a plurality of mobile vehicles (49D, 49E, 49F, 49G), each having two pumps (70) with associated motors (not shown) are depicted in communication with the variable frequency drives (66) and positioned in the hazard zone (5 IB).
  • the depicted embodiment can be used in high voltage applications (e.g.,. 4170 volts).
  • positioning components of the power subsystem (16) in close proximity to one another, e.g., on transportable vehicles (48A, 48B) can enable other synergistic benefits to be obtained.
  • air from one or more blowers used to cool the electric motors (68A, 68B, 68C, 68D) and/or maintain positive pressure therein could be channeled to the adjacent high pressure pumps (70A, 70B, 70C, 70D), e.g., by positioning each motor and associated high pressure pump in a single housing and/or connecting the housing of each motor to that of each associated pump via an air conduit.
  • Air from the blowers could thereby dissipate/disperse any propane or other alkanes and/or other flammable materials proximate to the pumps during operation, thereby preventing accumulation of flammable materials in a concentration that could be ignited.
  • the coupling and/or shaft connecting the motors to respective high pressure pumps could be provided with fins, blades, and/or other similar protrusions, such that rotation of the shaft can circulate air proximate to the high pressure pumps, and/or blower air from the motors can facilitate rotation of the shaft via the fins/protrusions by adding rotational motive force thereto.
  • Figure 2A depicts an embodiment of an electric-powered motor
  • a blower (74) associated therewith typically usable to provide air to the operative and/or moving parts of the motor (72), e.g., to cool the motor (72), represented by the air flowpath (76).
  • a drive shaft (80) of the motor (72) is shown extending therefrom to engage an adjacent pump (78) (e.g., a high pressure pump usable in fracturing operations). Rotation and/or other types of movement of the drive shaft (80) as the motor (72) is powered can thereby actuate the pump (78).
  • An air conduit (82) is shown extending between the motor (72) and the pump (78), such that air from the blower (76) can flow through the conduit (82) to the pump (72), as indicated by the flowpath (84), e.g., for dissipating gas proximate thereto.
  • FIG. 2B depicts an alternate embodiment in which the motor (72), blower (74), pump (78), and drive shaft (80) are shown.
  • an air conduit (86) is circumferentially disposed around the drive shaft (80), such that air from the blower (74) that moves across the motor (72), as indicated by the flowpath (86), can pass through the conduit (86), as indicated by the flowpath (88), e.g., to dissipate gas proximate to the pump (78).
  • FIG. 2C depicts an alternate embodiment in which the which the motor (72), blower (74), pump (78), and drive shaft (80) are shown, contained within a single housing (96). Air from the blower (74) that passes across the motor (72), as indicated by the flowpath (76), can therereby also flow proximate to the pump (78), as indicated by flowpaths (86A, 98B).
  • Figures 2A through 2C depict three possible methods by which air from a blower associated with a motor can be circulated in proximity to a pump, any method for conveying air to the pump can be used without departing from the scope of the present disclosure, and any of the features depicted in Figures 2A through 2C are usable singularly or in combination.
  • FIG 3 depicts an embodiment in which the motor (72), blower (74), pump (78), and drive shaft (80) are shown, in which the drive shaft (80) includes multiple protrusions (90A, 90B) (e.g., fins, blades, etc.) extending therefrom.
  • Air from the blower (74) can be provided, e.g., to cool the motor (72), as indicated by flowpath (76). The air can then flow, as indicated by flowpath (100), to contact one or more protrusions (90A, 90B), thereby imparting motive force thereto, and subsequently, to the drive shaft (80), such that the flow of air can cause additional rotation of the drive shaft (80), as indicated by the arrows (102A, 102B).
  • protrusions 90A, 90B
  • any number and placement/configuration of protrusions can be used without departing from the scope of the present disclosure.
  • protrusions extending from the drive shaft can be used singularly or in combination with any of the features shown in Figures 2A through 2C.
  • FIG 4 depicts an embodiment in which the protrusions (90A, 90B) are themselves usable as an air-moving device.
  • the motor (72), blower (74), pump (78), and drive shaft (80) are shown, in which the drive shaft (80) includes multiple protrusions (90A, 90B) extending therefrom. Movement of the drive shaft (80), e.g., imparted by the motor (72), as indicated by arrow (92), can thereby cause rotation of the protrusions (90A, 90B), which can be configured and/or oriented to circulate air proximate to the pump (78), as indicated by the flowpaths (94A, 94B).
  • Figure 5 depicts a diagrammatic side view of an embodiment of a variable frequency drive (104) usable within the scope of the present disclosure. It should be understood that while a variable frequency drive is depicted and described herein, the concept illustrated in Figure 5 is usable with any element of the system depicted in Figure 1. Specifically, during operations, it is possible for air at or proximate to the variable frequency drive (104) and/or other system components to become contaminated (e.g., with volatile gasses when using propane or similar components as a fracturing fluid, or with other fluids/gas ses depending on the operations being performed).
  • contaminated e.g., with volatile gasses when using propane or similar components as a fracturing fluid, or with other fluids/gas ses depending on the operations being performed.
  • a region of contaminated air (108) is shown proximate to the top of the variable frequency drive (104), while generally clean air (111) (e.g., lacking contaminants heavier than air) is shown above the contaminated air (108).
  • the variable frequency drive (104) may be necessary for the variable frequency drive (104) to intake air (e.g., for cooling and/or for operation thereof), while the intake of propane, volatile components, and/or other contaminants would be undesirable.
  • Figure 5 depicts an air conduit (106) (e.g., a "snorkel") extending from and/or otherwise engaged with the variable frequency drive (104) for communicating clean air (111) into the variable frequency drive (104), while isolating the variable frequency drive (104) from contaminated air.
  • Figure 7 depicts an embodiment of a system usable within the scope of the present disclosure. Specifically, Figure 7 depicts a system usable to inject a fluid under pressure into a well (150), e.g., to stimulate production of hydrocarbons or other products by forming fractures in the wellbore formation. While conventional fracturing operations provide a pressurized fracturing fluid into a well, mixed with proppant (e.g., solid particulate matter) to maintain and/or support the fractures while permitting the flow of hydrocarbons or other fluids from the formation into the wellbore and toward the surface, the depicted embodiment is usable to flow a fluidized solid proppant, substantially free of liquid.
  • proppant e.g., solid particulate matter
  • Figure 7 divides the depicted system into a proppant addition subsystem (110) for providing proppant into the well (150), a pumping subsystem (136) for pressurizing proppant and/or other flowstreams for injection into the well (150), and a fluid subsystem (142), which can be used to provide fluid into the well (150), e.g., to form fractures in the formation prior to the flowing of proppant thereto and/or to displace unused proppant from the well (150).
  • a proppant addition subsystem (110) for providing proppant into the well (150
  • a pumping subsystem (136) for pressurizing proppant and/or other flowstreams for injection into the well (150
  • a fluid subsystem (142) which can be used to provide fluid into the well (150), e.g., to form fractures in the formation prior to the flowing of proppant thereto and/or to displace unused proppant from the well (150).
  • the depicted proppant addition subsystem (110) is shown including a proppant storage vessel (112), and an additive storage vessel (114), both of which can include, for example, a silo, tank, hopper, or any other type of container or vessel usable to contain particulate solid matter.
  • a proppant storage vessel (112) can include, for example, a silo, tank, hopper, or any other type of container or vessel usable to contain particulate solid matter.
  • Use of vertically oriented proppant storage vessels, such as silos can enable gravity and/or the weight of the contents within the vessels (112, 114) to drive the contents from the containers, while also reducing the footprint presented by the containers.
  • One exemplary storage container could include a Model 424 Sand Silo, produced by Loadcraft Industries, LTD of Brady, Texas, which can include an associated transportation trailer.
  • the proppant storage vessel (112) can contain solid particulate matter (e.g., sand, ceramic, glass, clay, gravel, and/or other suitable materials usable as proppant), which can be flowed, pumped, and/or otherwise transferred, e.g., via a conduit (116) to a hopper (120) or other type of container.
  • the conduit (116) can include a conveyor, chute, trough, pipe, or any other suitable means usable to transport solid particulate matter, accompanied by any manner of associated valves, doors, pumps, or other types of control mechanisms usable to regulate the passage of proppant from the proppant storage vessel (112).
  • the proppant storage vessel (112) could be positioned in direct association with the hopper (120), such that a conduit is not necessary.
  • the proppant storage vessel (112) could be positioned above the hopper (120), such that proppant could fall directly into the hopper (120).
  • the additive storage vessel (114) can contain a solid, friction-reducing additive, such as molybdenum disulfide, carbon black, graphite, fumed silica, epoxy matrix resin nanoparticles, glass bubbles, and/or any other solid additive or liquid additive (e.g., silicone) capable of forming a friction-reducing coating about one or more particles of proppant and/or occupying spaces between particles of proppant to reduce friction therebetween and facilitate the flow thereof.
  • a solid, friction-reducing additive such as molybdenum disulfide, carbon black, graphite, fumed silica, epoxy matrix resin nanoparticles, glass bubbles, and/or any other solid additive or liquid additive (e.g., silicone) capable of forming a friction-reducing coating about one or more particles of proppant and/or occupying spaces between particles of proppant to reduce friction therebetween and facilitate the flow thereof.
  • the contents of the additive storage vessel (114) can be transferred to the hopper (120) via a conduit (118), which can include any manner of conveyor, chute, trough, pipe, or other suitable means, accompanied by associated valves, doors, pumps, or other types of control mechanisms usable to regulate the passage of the additive from the additive storage vessel (114).
  • a conduit (118) can include any manner of conveyor, chute, trough, pipe, or other suitable means, accompanied by associated valves, doors, pumps, or other types of control mechanisms usable to regulate the passage of the additive from the additive storage vessel (114).
  • the additive storage vessel (114) could be positioned in direct association with the hopper (120), such that the conduit (118) is not necessary.
  • Figure 7 depicts a hopper (120), adapted to receive contents from the proppant and additive storage vessels (112, 114), in various embodiments, the hopper (120) could include an auger, a blender, or other types of mixing devices usable to facilitate the combination of the proppant and additive materials (e.g., to coat and/or thoroughly mix the contents of the hopper (120)).
  • a lubricant source (122) depicted as a tank, can be used to dispense a fluid (e.g., mineral oil, water, fracturing fluid, or any other suitable lubricant that is compatible with the proppant and additive materials) into the hopper (120) via a conduit (126) and associated pump (124).
  • a fluid e.g., mineral oil, water, fracturing fluid, or any other suitable lubricant that is compatible with the proppant and additive materials
  • the lubricant can be used, generally, to facilitate mixing of the proppant and additive materials, and/or to facilitate the flow thereof; however, during typical use, the quantity of lubricant dispensed into the hopper (120) can be insufficient to form a slurry with the proppant materials.
  • Figure 7 illustrates a separate proppant storage vessel (112) and additive storage vessel (114), that dispense contents to a hopper (120) via separate conduits (116, 118), for mixing thereof
  • the depicted configuration is exemplary of a single illustrative embodiment.
  • the vessels (112, 114) could dispense respective contents into a single, merged conduit, where the proppant and additive mix, such that use of a separate hopper within which the proppant and additive can be combined is unnecessary.
  • the proppant, any additive materials, and a lubricant, if used can be prepared off-site, and a single container of fluidized solid proppant can be present, in lieu of the depicted storage vessels (112, 114), hopper (120), and lubricant source (122).
  • the proppant and additive can be prepared off-site, and dispensed from a single container, facilitated by the lubricant source (122).
  • the proppant and lubricant, or additive and lubricant could be mixed off-site, then combined with the remaining components at an operational site.
  • a fluidized solid proppant could be used in the absence of a friction-reducing additive.
  • glass bubbles and/or microspheres such as those made by 3M of St. Paul, Minnesota, could be used as a fluidized solid proppant, in the absence of an additional friction-reducing additive.
  • Use of a hopper (120) could be omitted (e.g., due to the lack of a need to mix components).
  • an inert gas could be provided in association with the hopper to prevent the introduction of air and/or oxygen into the system.
  • various types of pumps and/or other devices can be used to vibrate and/or pulse system conduits and/or vessels, as needed, to vibrate the fluidized solid proppant to reduce friction between particles thereof, allowing the proppant to flow in the manner of a liquid.
  • a pneumatic conveying system could be used to project a fluid to pulse and/or vibrate sand or similar particulate matter to facilitate flow thereof.
  • the proppant storage vessel (112) is shown in fluid communication with the well (150).
  • the hopper (120) is configured to dispense fluidized solid proppant via a conduit (128) (e.g., a pipe or similar member able to transport fluids to the well (150)), assisted by a booster pump (130) (e.g., a positive displacement pump or similar type of pump), to a low pressure region (132) of the conduit.
  • a conduit (128) e.g., a pipe or similar member able to transport fluids to the well (150)
  • a booster pump (130) e.g., a positive displacement pump or similar type of pump
  • the term "fluidized solid proppant” is used to describe, in general terms, solid matter (e.g., particulate matter) that flows in the manner of a liquid when transported under certain conditions (e.g., a threshold pressure and/or velocity) while functioning in the manner of a solid when stationary and/or under a pressure less than the threshold pressure.
  • the booster pump (130) and/or other associated equipment, conduits, etc. can be configured to dispense the fluidized solid proppant toward the well (150) under pressure/velocity conditions that enable the proppant to flow in the manner of a liquid, while remaining substantially free of liquid components.
  • the fluidized solid proppant while not wholly void of liquid, could be termed "substantially free" of liquid when the quantity of liquid mixed therewith is insufficient to form a slurry with the proppant.
  • the booster pump (130) and/or other pumps associated with the transport of proppant could be provided in a non- horizontal orientation.
  • the pumping subsystem (136) is shown in communication with the low pressure region (132). Specifically, two transportable pumping units (138A, 138B) are shown, each having a high pressure fracturing pump (140A, 140B) positioned thereon. While Figure 7 depicts two pumping units (138A, 138B), each having a single pump thereon, it should be understood that the depicted embodiment is an illustrative diagram, and any number and configuration of pumping units, having any number of pumps and/or other equipment associated therewith (e.g., power sources, motors, drivers, etc.) can be used without departing from the scope of the present disclosure. Examples of usable pumping systems are described previously.
  • the fluidized solid proppant in the low pressure region (132) flows toward the well, it is pressurized by the high pressure fracturing pumps (140A, 140B), defining a high pressure region (134) of the conduit.
  • the proppant can be provided into the well (150) at a pressure sufficient to generate fractures in the formation.
  • the flow rate provided by the pumps (140A, 140B) can then be reduced, thereby slowing the velocity of the proppant, such that at least a portion of the proppant engages the formation and remains within the fractures, thereby maintaining and/or supporting the fractures.
  • FIG. 7 depicts a fluid supply subsystem (142) that includes a tank (144) usable to contain one or more fluid media usable as a fracturing fluid (e.g., to form fractures in the wellbore formation when pressurized).
  • a fluid supply subsystem (142) that includes a tank (144) usable to contain one or more fluid media usable as a fracturing fluid (e.g., to form fractures in the wellbore formation when pressurized).
  • the depicted tank (144) could contain water, liquid petroleum gas (e.g., as described in U.S.
  • Patent 8,408,289 incorporated by reference above
  • propane and/or other alkanes or hydrocarbons described above and in the United States Provisional Application for patent, having the Application Serial Number 61/889,187 filed October 10, 2013, incorporated by reference above, halogenated hydrocarbons, as described above and in Applications 61/889,187 and 61/807,699, incorporated by reference above, propylene carbonate, as described above and in Application 61/870,350, incorporated by reference above, or any other fracturing fluid known in the art.
  • Figure 7 depicts a single tank (144), it should be understood that any number and configuration of vessels and/or pipelines can be used to supply fluid to the well (150) without departing from the scope of the present disclosure.
  • Use of vertically- oriented tanks to contain fracturing fluids (including volatile fluids) can enable gravity and/or vapor pressure above the contents of the tanks to aid in driving the contents toward the well (150), thus requiring lower energy and/or lower power pumping equipment, while also enabling the tanks to include a smaller quantity of unused volume (e.g., "tank bottoms") when compared to a horizontally-oriented tank.
  • Vertical tanks also provide a smaller footprint than horizontal tanks and other alternatives.
  • the depicted tank (144) is configured to dispense fluid, via a conduit (146), assisted by a booster pump (148) toward the low pressure region (132).
  • the high pressure fracturing pumps (140A, 140B) are usable to pressurized the fluid to a pressure sufficient to form fractures in the formation.
  • fluidized solid proppant can be flowed into the well (150), as described above, subsequent to the use of fracturing fluid, thereby displacing the fracturing fluid from the well (50) and engaging proppant with fractures in the formation.
  • additional fluid e.g., fracturing fluid or a displacement fluid from a separate source (not shown)
  • fracturing fluid e.g., fracturing fluid or a displacement fluid from a separate source (not shown)
  • a separate source e.g., fracturing fluid or a displacement fluid from a separate source (not shown)
  • additional fluid can be pumped into the well (150) to displace fluidized solid proppant not engaged with the formation.
  • Figures 8 A through 8D depict a diagrammatic view of a wellbore (152), illustrating an embodiment of a method usable within the scope of the present disclosure.
  • Figure 8A depicts the wellbore having an internal bore (154) (e.g., of a casing string), an annular region (156) disposed circumferentially about the inner bore (154) (e.g., between the formation wall and the casing string), and a plurality of perforations of which a single perforation (158) is labeled for reference.
  • the internal bore (154), annular region (156), and/or perforations (158) can be filled various wellbore fluids and/or other materials known in the art.
  • a fracturing fluid (160) e.g., water, hydrocarbons, etc.
  • a fracturing fluid (160) can be injected, at high pressure, to the perforations (158). While Figure 8B depicts a fracturing fluid (160) primarily occupying the inner bore (154), it should be understood that during a typical fracturing operation, the generally continuous flow of pressurized fluid can continue such that fracturing fluid occupies the inner bore (154) and perforations (158).
  • the force and/or pressure applied by the fluid (160) to the formation can cause the formation of fractures, of which a single fracture (162) is labeled for reference, at or proximate to the perforations (158).
  • a fluidized solid proppant (164) can be flowed to the fractures (162), displacing the fracturing fluid (160). While Figure 8C depicts fluidized solid proppant (164) primarily occupying the inner bore (154), an operation can include the generally continuous flow of fluidized solid proppant, such that the proppant occupies the inner bore (154) perforations (158), and fractures (162).
  • At least a portion of the proppant (166) can enter the fractures (162), such that the release of pressure (e.g., applied from the surface) can cause the fluidized solid proppant (164) to slow and/or settle, such that the portion of the proppant (166) engages the fractures (162) to maintain and/or stabilize the fractures (162) in an open position conducive to production.
  • the release of pressure e.g., applied from the surface
  • the fluidized solid proppant (164) can cause the fluidized solid proppant (164) to slow and/or settle, such that the portion of the proppant (166) engages the fractures (162) to maintain and/or stabilize the fractures (162) in an open position conducive to production.
  • Figure 9A depicts an embodiment of a composition usable within the scope of the present disclosure.
  • Figure 9A depicts an embodiment of a fluidized solid proppant material, of which an exemplary particle of proppant (170) has been labeled for reference.
  • the depicted proppant (170) includes a core (172) of solid particulate material that can include, for example, sand, ceramic, clay, gravel, glass, or any other material having sufficient structural strength to maintain and/or support a fracture within a wellbore formation.
  • a coating (174) of a solid, friction-reducing material is shown disposed about the core (172).
  • Usable coatings can include, for example, molybdenum disulfide, carbon black, graphite, fumed silica, and/or epoxy matrix resin nanoparticles, which can be mixed with solid particulate matter (e.g., the core (112)) until the core is substantially coated, as depicted.
  • a liquid coating such as silicone can also be used.
  • a lubricant or similar liquid can be provided, e.g., to wet the materials and/or promote mixing thereof; however, it should be noted that the quantity of liquid can generally be insufficient to form a slurry with the proppant (170).
  • Figure 9A depicts spaces (175) and/or interstices between the adjacent particles of proppant (170), which can be occupied by a lubricant or other fluid, as desired.
  • the friction-reducing coating (174) on each particle of proppant (170) enables the proppant (170) to flow in the manner of a liquid when moved under certain threshold conditions (e.g., pressure, velocity, etc.), due to the reduction of friction between adjacent particles, while functioning in the manner of a solid when stationary and/or under a pressure less than the threshold pressure.
  • certain threshold conditions e.g., pressure, velocity, etc.
  • Figure 9B depicts an embodiment of a composition usable within the scope of the present disclosure.
  • Figure 9B depicts an embodiment of a fluidized solid proppant material that includes particles of proppant (176), which can include, for example, sand, ceramic, clay, gravel, glass, or any other material having sufficient structural strength to maintain and/or support a fracture within a wellbore formation.
  • the proppant (176) can be mixed with particles of a solid, friction-reducing material (180), such as molybdenum disulfide, carbon black, graphite, fumed silica, glass bubbles, and/or epoxy matrix resin nanoparticles, which can occupy the interstices (178) between particles of proppant (176).
  • a solid, friction-reducing material such as molybdenum disulfide, carbon black, graphite, fumed silica, glass bubbles, and/or epoxy matrix resin nanoparticles
  • a lubricant or similar liquid can be provided, e.g., to wet the materials and/or promote mixing thereof (e.g., the liquid could occupy the interstices (178)); however, it should be noted that the quantity of liquid can generally be insufficient to form a slurry with the proppant (176).
  • the presence of the friction-reducing additive (180) between particles of proppant (176) can enable the proppant (176) to flow in the manner of a liquid when moved at a sufficient velocity, due to the reduction of friction between adjacent particles, while functioning in the manner of a solid when stationary and/or moving at a slower velocity.
  • Figures 9 A and 9B depict mixtures of proppant particles with solid-friction reducing additives
  • materials that can flow in the manner of a liquid in the absence of any friction- reducing additives and/or coatings can be used.
  • glass bubbles and/or microspheres can be provided with an external surface having reduced frictional interactions with adjacent particles.
  • vibration and/or pulsing of proppant materials can be used to reduce friction between particles thereof to enable the proppant materials to flow, e.g., in the substantial absence of liquid.

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  • General Life Sciences & Earth Sciences (AREA)
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  • Geochemistry & Mineralogy (AREA)
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Abstract

L'invention concerne des systèmes, des unités et des procédés utilisables pour stimuler une formation qui comprennent un premier sous-système d'alimentation adapté pour fournir un premier milieu à la formation et un sous-système de pression qui comprend une pompe en communication avec le premier milieu pour mettre sous pression le premier milieu à une pression suffisante pour stimuler la formation. Les milieux utilisables peuvent comprendre des alcanes liquides non gélifiés, des hydrocarbures halogénés, des hydrocarbures émulsifiés, un carbonate de propylène, une matière d'agent de soutènement solide fluidisée qui se comporte comme un liquide dans des conditions de seuil, ou une matière liquide conçue pour se solidifier dans des conditions de seuil. Un agent de soutènement peut être introduit en addition au premier milieu lors de la réalisation d'opérations de fracturation. L'agent de soutènement utilisable peut comprendre des matières ayant une dimension ou une densité conçue pour faciliter la flottabilité, des matières creuses, des matières composites, des matières poreuses ou des matières cristallines.
EP14759998.9A 2013-03-07 2014-03-06 Systèmes de fracturation et procédés pour un puits de forage Withdrawn EP2981669A4 (fr)

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US201361774237P 2013-03-07 2013-03-07
US201361790942P 2013-03-15 2013-03-15
US201361807699P 2013-04-02 2013-04-02
US201361870350P 2013-08-27 2013-08-27
US201361889187P 2013-10-10 2013-10-10
US201361915093P 2013-12-12 2013-12-12
PCT/US2014/021382 WO2014138468A1 (fr) 2013-03-07 2014-03-06 Systèmes de fracturation et procédés pour un puits de forage

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WO2014138468A1 (fr) 2014-09-12

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