US008789601 B2
`
`(12) United States Patent
`BrOussard et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8,789,601 B2
`*Jul. 29, 2014
`
`(54) SYSTEM FOR PUMPING HYDRAULIC
`FRACTURING FLUID USINGELECTRIC
`PUMPS
`
`(71) Applicant: US Well Services LLC, Houston, TX
`(US)
`
`(72) Inventors: Joel N. Broussard, Lafayette, LA (US);
`Jeff McPherson, Spring, TX (US);
`Robert Kurtz, Fairmont, WV (US)
`
`(*) Notice:
`
`(73) Assignee: US Well Services LLC, Houston, TX
`(US)
`Subject to any disclaimer, the term of this
`past lSo G adjusted under 35
`M
`YW-
`y
`yS.
`This patent is Subject to a terminal dis-
`claimer.
`
`(21) Appl. No.: 14/190,982
`1-1.
`(22) Filed:
`(65)
`
`Feb. 26, 2014
`Prior Publication Data
`US 2014/O174717 A1
`Jun. 26, 2014
`O
`O
`Related U.S. Application Data
`(63) Continuation-in-part of application No. 13/679,.689,
`filed on Nov. 16, 2012.
`
`(51) Int. Cl.
`E2IB 43/26
`
`(2006.01)
`
`
`
`(52) U.S. Cl.
`CPC ...................................... E2IB 43/26 (2013.01)
`USPC ..................................... 166/308.1: 166/177.5
`(58) Field of Classification Search
`USPC ............................................ 166/308.1, 177.5
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`2012,0255734 A1 10, 2012 Coli et al.
`2013/0306322 A1* 11/2013 Sanborn et al. ............ 166,308.1
`2014/0010671 A1* 1/2014 Cryer et al. ..................... 417/53
`* cited by examiner
`Primary Examiner – William P Neuder
`(74) Attorney, Agent, or Firm — Bracewell & Giuliani LLP:
`Jeffrey S. Whittle: Taylor P. Evans
`
`ABSTRACT
`(57)
`A system for hydraulically fracturing an underground forma
`tion in an oil orgas well to extract oil orgas from the forma
`tion, the oil orgas well having a wellbore that permits passage
`of fluid from the wellbore into the formation. The system
`includes a plurality of pumps powered by electric induction
`motors and fluidly connected to the well, the pumps config
`ured to pump fluid into the wellbore at high pressure so that
`the fluid passes from the wellbore into the, and fractures the
`formation. The system can also include a plurality of natural
`gas powered generators electrically connected to the plurality
`of pumps to provide electrical power to the pumps.
`
`22 Claims, 4 Drawing Sheets
`
`HALLIBURTON EXHIBIT 1049
`Halliburton Energy Services, Inc. v. U.S. Well Services, LLC, IPR2023-00558, Page 1
`
`

`

`U.S. Patent
`
`Jul. 29, 2014
`
`Sheet 1 of 4
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`US 8,789,601 B2
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`HALLIBURTON EXHIBIT 1049
`Halliburton Energy Services, Inc. v. U.S. Well Services, LLC, IPR2023-00558, Page 2
`
`

`

`U.S. Patent
`
`Jul. 29, 2014
`
`Sheet 2 of 4
`
`US 8,789,601 B2
`
`
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`HALLIBURTON EXHIBIT 1049
`Halliburton Energy Services, Inc. v. U.S. Well Services, LLC, IPR2023-00558, Page 3
`
`

`

`U.S. Patent
`
`Jul. 29, 2014
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`HALLIBURTON EXHIBIT 1049
`Halliburton Energy Services, Inc. v. U.S. Well Services, LLC, IPR2023-00558, Page 4
`
`

`

`U.S. Patent
`
`Jul. 29, 2014
`
`Sheet 4 of 4
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`US 8,789,601 B2
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`HALLIBURTON EXHIBIT 1049
`Halliburton Energy Services, Inc. v. U.S. Well Services, LLC, IPR2023-00558, Page 5
`
`

`

`1.
`SYSTEM FOR PUMPNG HYDRAULC
`FRACTURING FLUID USINGELECTRIC
`PUMPS
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This application is a continuation-in-part of, and claims
`priority to and the benefit of U.S. patent application Ser. No.
`13/679,.689, which was filed Nov. 16, 2012, the full disclosure
`of which is incorporated herein by reference.
`
`BACKGROUND OF THE INVENTION
`
`1. Field of the Invention
`This technology relates to hydraulic fracturing in oil and
`gas wells. In particular, this technology relates to pumping
`fracturing fluid into an oil or gas well using pumps powered
`by electric motors.
`2. Brief Description of Related Art
`Hydraulic fracturing has been used for decades to stimulate
`production from conventional oil and gas wells. The practice
`consists of pumping fluid into a wellbore at high pressure.
`Inside the wellbore, the fluid is forced into the formation
`being produced. When the fluid enters the formation, it frac
`tures, or creates fissures, in the formation. Water, as well as
`other fluids, and some solid proppants, are then pumped into
`the fissures to stimulate the release of oil and gas from the
`formation.
`Fracturing rock in a formation requires that the fracture
`fluid be pumped into the wellbore at very high pressure. This
`pumping is typically performed by large diesel-powered
`pumps. Such pumps are able to pump fracturing fluid into a
`wellbore at a high enough pressure to crack the formation, but
`they also have drawbacks. For example, the diesel pumps are
`very heavy, and thus must be moved on heavy duty trailers,
`making transport of the pumps between oilfield sites expen
`sive and inefficient. In addition, the diesel engines required to
`drive the pumps require a relatively high level of expensive
`maintenance. Furthermore, the cost of diesel fuel is much
`higher than in the past, meaning that the cost of running the
`pumps has increased.
`What is needed therefore, is a pump system for hydraulic
`fracturing fluid that overcomes the problems associated with
`diesel pumps.
`
`10
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`15
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`25
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`30
`
`35
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`40
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`45
`
`SUMMARY OF THE INVENTION
`
`Disclosed herein is a system for hydraulically fracturing an
`underground formation in an oil or gas well to extract oil or
`gas from the formation, the oil or gas well having a wellbore
`that permits passage of fluid from the wellbore into the for
`mation. The system includes a plurality of pumps powered by
`electric induction motors and fluidly connected to the well,
`the pumps configured to pump fluid into the wellbore at high
`pressure so that the fluid passes from the wellbore into the
`formation, and fractures the formation. The system also
`includes a plurality of generators electrically connected to the
`plurality of pumps to provide electrical power to the pumps.
`At least some of the plurality of generators can be powered by
`natural gas. In addition, at least some of the plurality of
`generators can be turbine generators.
`In one embodiment, the system further includes an A/C
`console and a variable frequency drive that controls the speed
`of the pumps. Furthermore, the pumps, as well as the electric
`
`50
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`60
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`US 8,789,601 B2
`
`2
`generators, can be mounted on vehicles, and can be ported
`from one well to another. The vehicles can be trucks and can
`have at least five axles.
`Further disclosed herein is a system for fracturing a rock
`formation in an oil or gas well by pumping hydraulic fractur
`ing fluid into the well that includes a pump, an electric induc
`tion motor, a variable frequency drive, and a natural gas
`powered electric generator. The pump is configured for
`pumping the hydraulic fracturing fluid into the well, and then
`from the well into the formation, and is capable of pumping
`the hydraulic fracturing fluid at high pressure to crack the
`formation. The electric induction motor can have a high
`strength steel or steel alloy drive drive shaft attached to the
`pump and configured to drive the pump. The variable fre
`quency drive can be connected to the electric motor to control
`the speed of the motor. In addition, the natural gas powered
`generator, which can be a turbine generator, can be connected
`to the electric induction motor and provide electric power to
`the electric induction motor.
`In one embodiment, the pump can be a triplex or a quintu
`plex pump, optionally rated at about 2250 horsepower or
`more. In addition, the pump can also have 4.5 inch diameter
`plungers with an eight inch stroke. In another embodiment,
`the electric motor can have a maximum continuous power
`output of about 1500 horsepower, 1750 horsepower, or more,
`and a maximum continuous torque of about 8750 ft-lb.
`11,485 ft-lb, or more. Furthermore, the electric motor can
`have a high temperature rating of about 1100 degrees C. or
`more, and a drive shaft composed of 4340 alloy steel. Of
`course, the technology is not limited to the use of drive shaft
`made from such an alloy. For example, the drive shaft can be
`made from any suitable material.
`In another embodiment, variable frequency drive can fre
`quently perform electric motor diagnostics to prevent damage
`to the electric motor if it becomes grounded or shorted. In
`addition, the variable frequency drive can include power
`semiconductor heat sinks having one or more thermal sensors
`monitored by a microprocessor to prevent semiconductor
`damage caused by excessive heat.
`Also disclosed herein is a system for hydraulically fractur
`ing an underground formation in an oil or gas well to extract
`oil or gas from the formation, the oil or gas well having a
`wellbore that permits passage of fluid from the wellbore into
`the formation. The system includes a trailer. Two or more
`pumps can be attached to the trailer and are fluidly connected
`to the well, the pumps configured to pump fluid into the
`wellbore at high pressure so that the fluid passes from the
`wellbore into the formation, and fractures the formation. One
`or more electric induction motors are attached to the pumps to
`drive the pumps. The electric induction motors can also be
`attached to the trailer. A natural gas powered generator is
`provided for connection to the electric induction motor to
`provide electric power to the electric induction motor. The
`system of claim can further include a variable frequency drive
`attached to the trailer and connected to the electric induction
`motor to control the speed of the motor. In addition, the
`system can include a skid to which at least one of the pumps,
`the one or more electric motors, and the variable frequency
`drives are attached.
`Also disclosed herein is a process for stimulating an oil or
`gas well by hydraulically fracturing a formation in the well.
`The process includes the steps of pumping fracturing fluid
`into the well with an electrically powered pump at a high
`pressure so that the fracturing fluid enters and cracks the
`formation, the fracturing fluid having at least a liquid com
`ponent and a solid proppant, and inserting the Solid proppant
`into the cracks to maintain the cracks open, thereby allowing
`
`HALLIBURTON EXHIBIT 1049
`Halliburton Energy Services, Inc. v. U.S. Well Services, LLC, IPR2023-00558, Page 6
`
`

`

`US 8,789,601 B2
`
`3
`passage of oil and gas through the cracks. The process can
`further include powering the electrically powered pump with
`a natural gas generator, such as, for example, a turbine gen
`eratOr.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`The present technology will be better understood on read
`ing the following detailed description of nonlimiting embodi
`ments thereof, and on examining the accompanying drawing,
`in which:
`FIG. 1 is a schematic plan view of equipment used in a
`hydraulic fracturing operation, according to an embodiment
`of the present technology;
`FIG. 2 is a schematic plan view of equipment used in a
`hydraulic fracturing operation, according to an alternate
`embodiment of the present technology;
`FIG. 3 is a left side view of equipment used to pump
`fracturing fluid into a well and mounted on a trailer, according
`to an embodiment of the present technology; and
`FIG. 4 is a right side view of the equipment and trailer
`shown in FIG. 3.
`
`10
`
`15
`
`DETAILED DESCRIPTION OF THE PREFERRED
`EMBODIMENT
`
`25
`
`4
`system, including the pumps 10 and the electric motors 14,
`can be capable of operating during prolonged pumping opera
`tions, and in temperature in a range of about 0 degrees C. or
`less to about 55 degrees C. or more. In addition, each electric
`motor 14 can be equipped with a variable frequency drive
`(VFD) 15, and an A/C console, that controls the speed of the
`electric motor 14, and hence the speed of the pump 10.
`The VFDS 15 of the present technology can be discrete to
`each vehicle 12 and/or pump 10. Such a feature is advanta
`geous because it allows for independent control of the pumps
`10 and motors 14. Thus, if one pump 10 and/or motor 14
`becomes incapacitated, the remaining pumps 10 and motors
`14 on the vehicle 12 or in the fleet can continue to function,
`thereby adding redundancy and flexibility to the system. In
`addition, separate control of each pump 10 and/or motor 14
`makes the system more scalable, because individual pumps
`10 and/or motors 14 can be added to or removed from a site
`without modification to the VFDS 15.
`The electric motors 14 of the present technology can be
`designed to withstand an oilfield environment. Specifically,
`Some pumps 10 can have a maximum continuous power out
`put of about 1500 HP, 1750 HP, or more, and a maximum
`continuous torque of about 8750 ft-lb. 11,485 ft-lb. or more.
`Furthermore, electric motors 14 of the present technology can
`include class H insulation and high temperature ratings, such
`as about 1100 degrees C. or more. In some embodiments, the
`electric motor 14 can include a single shaft extension and hub
`for high tension radial loads, and a high strength 4340 alloy
`steel drive shaft, although other suitable materials can also be
`used.
`The VFD 15 can be designed to maximize the flexibility,
`robustness, serviceability, and reliability required by oilfield
`applications, such as hydraulic fracturing. For example, as far
`as hardware is concerned, the VFD 15 can include packaging
`receiving a high rating by the National Electrical Manufac
`turers Association (such as nema 1 packaging), and power
`semiconductor heat sinks having one or more thermal sensors
`monitored by a microprocessor to prevent semiconductor
`damage caused by excessive heat. Furthermore, with respect
`to control capabilities, the VFD 15 can provide complete
`monitoring and protection of drive internal operations while
`communicating with an operator via one or more user inter
`faces. For example, motor diagnostics can be performed fre
`quently (e.g., on the application of power, or with each start),
`to prevent damage to a grounded or shorted electric motor 14.
`The electric motor diagnostics can be disabled, if desired,
`when using, for example, a low impedance or high-speed
`electric motor.
`In some embodiments, the pump 10 can optionally be a
`2250 HP triplex or quintuplex pump. The pump 10 can
`optionally be equipped with 4.5 inch diameter plungers that
`have an eight (8) inch stroke, although other size plungers can
`be used, depending on the preference of the operator. The
`pump 10 can further include additional features to increase its
`capacity, durability, and robustness, including, for example, a
`6.353 to 1 gear reduction, autofrettaged steel or steel alloy
`fluid end, wing guided slush type valves, and rubber spring
`loaded packing. Alternately, pumps having slightly different
`specifications could be used. For example, the pump 10 could
`be equipped with 4 inch diameter plungers, and/or plungers
`having a ten (10) inch stroke.
`In addition to the above, certain embodiments of the
`present technology can optionally include a skid (not shown)
`for Supporting some or all of the above-described equipment.
`For example, the skid can Support the electric motor 14 and
`the pump 10. In addition, the skid can support the VFD 15.
`Structurally, the skid can be constructed of heavy-duty lon
`
`30
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`
`The foregoing aspects, features, and advantages of the
`present technology will be further appreciated when consid
`ered with reference to the following description of preferred
`embodiments and accompanying drawing, wherein like ref
`erence numerals represent like elements. In describing the
`preferred embodiments of the technology illustrated in the
`appended drawing, specific terminology will be used for the
`sake of clarity. However, the technology is not intended to be
`limited to the specific terms used, and it is to be understood
`that each specific term includes equivalents that operate in a
`similar manner to accomplish a similar purpose.
`FIG. 1 shows a plan view of equipment used in a hydraulic
`fracturing operation. Specifically, there is shown a plurality of
`pumps 10 mounted to vehicles 12, Such as trailers (as shown,
`40
`for example, in FIGS.3 and 4). In the embodiment shown, the
`pumps 10 are powered by electric motors 14, which can also
`be mounted to the vehicles 12. The pumps 10 are fluidly
`connected to the wellhead 16 via the missile 18. As shown, the
`vehicles 12 can be positioned near enough to the missile 18 to
`connect fracturing fluid lines 20 between the pumps 10 and
`the missile 18. The missile 18 is then connected to the well
`head 16 and configured to deliver fracturing fluid provided by
`the pumps 10 to the wellhead 16. Although the vehicles 12 are
`shown in FIGS. 3 and 4 to be trailers, the vehicles could
`alternately be trucks, wherein the pumps 10, motors 14, and
`other equipment are mounted directly to the truck.
`In some embodiments, each electric motor 14 can be an
`induction motor, and can be capable of delivering about 1500
`horsepower (HP), 1750HP, or more. Use of induction motors,
`and in particular three-phase induction motors, allows for
`increased power output compared to other types of electric
`motors, such as permanent magnet (PM) motors. This is
`because three-phase induction motors have nine poles (3
`poles per phase) to boost the power factor of the motors.
`Conversely, PM motors are synchronous machines that are
`accordingly limited in speed and torque. This means that for
`a PM motor to match the power output of a three-phase
`induction motor, the PM motor must rotate very fast, which
`can lead to overheating and other problems.
`Each pump 10 can optionally be rated for about 2250
`horsepower (HP) or more. In addition, the components of the
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`HALLIBURTON EXHIBIT 1049
`Halliburton Energy Services, Inc. v. U.S. Well Services, LLC, IPR2023-00558, Page 7
`
`

`

`US 8,789,601 B2
`
`5
`gitudinal beams and cross-members made of an appropriate
`material. Such as, for example, Steel. The skid can further
`include heavy-duty lifting lugs, or eyes, that can optionally be
`of sufficient strength to allow the skid to be lifted at a single
`lift point. It is to be understood, however, that a skid is not
`necessary for use and operation of the technology, and the
`mounting of the equipment directly to a vehicle 12 without a
`skid can be advantageous because it enables quick transport
`of the equipment from place to place, and increased mobility
`of the pumping system.
`Referring back to FIG. 1, also included in the equipment is
`a plurality of electric generators 22 that are connected to, and
`provide powerto, the electric motors 14 on the vehicles 12. To
`accomplish this, the electric generators 22 can be connected
`to the electric motors 14 by power lines (not shown). The
`electric generators 22 can be connected to the electric motors
`14 via power distribution panels (not shown). In certain
`embodiments, the electric generators 22 can be powered by
`natural gas. For example, the generators can be powered by
`liquefied natural gas. The liquefied natural gas can be con
`Verted into a gaseous form in a vaporizer prior to use in the
`generators. The use of natural gas to power the electric gen
`erators 22 can be advantageous because above ground natural
`gas vessels 24 can already be placed on site in a field that
`produces gas in Sufficient quantities. Thus, a portion of this
`natural gas can be used to power the electric generators 22,
`thereby reducing or eliminating the need to import fuel from
`offsite. If desired by an operator, the electric generators 22
`can optionally be natural gas turbine generators, such as those
`shown in FIG. 2. The generators can run on any appropriate
`type of fuel, including liquefied natural gas (LNG).
`FIG. 1 also shows equipment for transporting and combin
`ing the components of the hydraulic fracturing fluid used in
`the system of the present technology. In many wells, the
`fracturing fluid contains a mixture of water, sand or other
`proppant, acid, and other chemicals. Examples of fracturing
`fluid components include acid, anti-bacterial agents, clay sta
`bilizers, corrosion inhibitors, friction reducers, gelling
`agents, iron control agents, pH adjusting agents, scale inhibi
`tors, and Surfactants. Historically, diesel has at times been
`used as a substitute for water in cold environments, or where
`a formation to be fractured is water sensitive, Such as, for
`example, clay. The use of diesel, however, has been phased
`out over time because of price, and the development of newer,
`better technologies.
`In FIG. 1, there are specifically shown sand transporting
`vehicles 26, an acid transporting vehicle 28, vehicles for
`transporting other chemicals 30, and a vehicle carrying a
`hydration unit 32. Also shown are fracturing fluid blenders
`34, which can be configured to mix and blend the components
`of the hydraulic fracturing fluid, and to supply the hydraulic
`fracturing fluid to the pumps 10. In the case of liquid compo
`nents, such as water, acids, and at least Some chemicals, the
`components can be supplied to the blenders 34 via fluid lines
`(not shown) from the respective component vehicles, or from
`the hydration unit 32. In the case of solid components, such as
`sand, the component can be delivered to the blender 34 by a
`conveyor belt 38. The water can be supplied to the hydration
`unit 32 from, for example, water tanks 36 onsite. Alternately,
`the water can be provided by water trucks. Furthermore,
`water can be provided directly from the water tanks 36 or
`water trucks to the blender 34, without first passing through
`the hydration unit 32.
`In certain embodiments of the technology, the hydration
`units 32 and blenders 34 can be powered by electric motors.
`For example, the blenders 34 can be powered by more than
`one motor, including motors having 600 horsepower or more,
`
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`and motors having 1150 horsepower or more. The hydration
`units 32 can be powered by electric motors of 600 horsepower
`or more. In addition, in some embodiments, the hydration
`units 32 can each have up to five (5) chemical additive pumps,
`and a 200 bbl steel hydration tank.
`Pump control and data monitoring equipment 40 can be
`mounted on a control vehicle 42, and connected to the pumps
`10, electric motors 14, blenders 34, and other downhole sen
`sors and tools (not shown) to provide information to an opera
`tor, and to allow the operator to control different parameters
`of the fracturing operation. For example, the pump control
`and data monitoring equipment 40 can include an A/C con
`sole that controls the VFD 15, and thus the speed of the
`electric motor 14 and the pump 10. Other pump control and
`data monitoring equipment can include pump throttles, a
`pump VFD fault indicator with a reset, a general fault indi
`cator with a reset, a main estop, a programmable logic con
`troller for local control, and a graphics panel. The graphics
`panel can include, for example, a touchscreen interface.
`Referring now to FIG. 2, there is shown an alternate
`embodiment of the present technology. Specifically, there is
`shown a plurality of pumps 110 which, in this embodiment,
`are mounted to pump trailers 112. As shown, the pumps 110
`can optionally be loaded two to a trailer 112, thereby mini
`mizing the number of trailers needed to place the requisite
`number of pumps at a site. The ability to load two pumps 110
`on one trailer 112 is possible because of the relatively light
`weight of the electric powered pumps 110 compared to other
`known pumps, such as diesel pumps. In the embodiment
`shown, the pumps 110 are powered by electric motors 114,
`which can also be mounted to the pump trailers 112. Further
`more, each electric motor 114 can be equipped with a VFD
`115, and an A/C console, that controls the speed of the motor
`114, and hence the speed of the pumps 110.
`The VFDS 115 shown in FIG. 2 can be discrete to each
`pump trailer 112 and/or pump 110. Such a feature is advan
`tageous because it allows for independent control of the
`pumps 110 and motors 114. Thus, if one pump 110 and/or
`motor 114 becomes incapacitated, the remaining pumps 110
`and motors 114 on the pump trailers 112 or in the fleet can
`continue to function, thereby adding redundancy and flexibil
`ity to the system. In addition, separate control of each pump
`110 and/or motor 114 makes the system more scalable,
`because individual pumps 110 and/or motors 114 can be
`added to or removed from a site without modification to the
`VFDS 115.
`In addition to the above, and still referring to FIG. 2, the
`system can optionally include a skid (not shown) for Support
`ing some or all of the above-described equipment. For
`example, the skid can Support the electric motors 114 and the
`pumps 110. In addition, the skid can support the VFD 115.
`Structurally, the skid can be constructed of heavy-duty lon
`gitudinal beams and cross-members made of an appropriate
`material. Such as, for example, Steel. The skid can further
`include heavy-duty lifting lugs, or eyes, that can optionally be
`of sufficient strength to allow the skid to be lifted at a single
`lift point. It is to be understood that a skid is not necessary for
`use and operation of the technology and the mounting of the
`equipment directly to a trailer 112 may be advantageous
`because if enables quick transport of the equipment from
`place to place, and increased mobility of the pumping system,
`as discussed above.
`The pumps 110 are fluidly connected to a wellhead 116 via
`a missile 118. As shown, the pump trailers 112 can be posi
`tioned near enough to the missile 118 to connect fracturing
`fluid lines 120 between the pumps 110 and the missile 118.
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`HALLIBURTON EXHIBIT 1049
`Halliburton Energy Services, Inc. v. U.S. Well Services, LLC, IPR2023-00558, Page 8
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`The missile 118 is then connected to the wellhead 116 and
`configured to deliver fracturing fluid provided by the pumps
`110 to the wellhead 116.
`This embodiment also includes a plurality of turbine gen
`erators 122 that are connected to, and provide power to, the
`electric motors 114 on the pump trailers 112. To accomplish
`this, the turbine generators 122 can be connected to the elec
`tric motors 114 by power lines (not shown). The turbine
`generators 122 can be connected to the electric motors 114 via
`power distribution panels (not shown). In certain embodi
`ments, the turbine generators 122 can be powered by natural
`gas, similar to the electric generators 22 discussed above in
`reference to the embodiment of FIG. 1. Also included are
`control units 144 for the turbine generators 122. The control
`units 144 can be connected to the turbine generators 122 in
`Such a way that each turbine generator 122 is separately
`controlled. This provides redundancy and flexibility to the
`system, so that if one turbine generator 122 is taken offline
`(e.g., for repair or maintenance), the other turbine generators
`122 can continue to function.
`The embodiment of FIG. 2 can include other equipment
`similar to that discussed above. For example, FIG. 2 shows
`sand transporting vehicles 126, acid transporting vehicles
`128, other chemical transporting vehicles 130, hydration unit
`132, blenders 134, water tanks 136, conveyor belts 138, and
`pump control and data monitoring equipment 140 mounted
`on a control vehicle 142. The function and specifications of
`each of these is similar to corresponding elements shown in
`FIG 1.
`Use of pumps 10, 110 powered by electric motors 14, 114
`and natural gas powered electric generators 22 (or turbine
`generators 122) to pump fracturing fluid into a well is advan
`tageous over known systems for many different reasons. For
`example, the equipment (e.g. pumps, electric motors, and
`generators) is lighter than the diesel pumps commonly used in
`the industry. The lighter weight of the equipment allows
`loading of the equipment directly onto a truck body or trailer.
`Where the equipment is attached to a skid, as described
`above, the skid itself can be lifted on the truck body, along
`with all the equipment attached to the skid. Furthermore, and
`as shown in FIGS. 3 and 4, trailers 112 can be used to trans
`port the pumps 110 and electric motors 114, with two or more
`pumps 110 carried on a single trailer 112. Thus, the same
`number of pumps 110 can be transported on fewer trailers
`112. Known diesel pumps, in contrast, cannot be transported
`directly on a truck body or two on a trailer, but must be
`transported individually on trailers because of the great
`weight of the pumps.
`The ability to transfer the equipment of the present tech
`nology directly on a truck body or two to a trailer increases
`efficiency and lowers cost. In addition, by eliminating or
`reducing the number of trailers to carry the equipment, the
`equipment can be delivered to sites having a restricted
`amount of space, and can be carried to and away from work
`sites with less damage to the Surrounding environment.
`Another reason that the electric powered pump system of the
`present technology is advantageous is that it runs on natural
`gas. Thus, the fuel is lower cost, the components of the system
`require less maintenance, and emissions are lower, so that
`potentially negative impacts on the environment are reduced.
`More detailed side views of the trailers 112, having various
`system components mounted thereon, are shown in FIGS. 3
`and 4, which show left and right side views of a trailer 112,
`respectively. As can be seen, the trailer 112 can be configured
`to carry pumps 110, electric motors 114 and a VFD 115. Thus
`configured, the motors 114 and pumps 110 can be operated
`and controlled while mounted to the trailers 112. This pro
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`US 8,789,601 B2
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`vides advantages such as increased mobility of the system.
`For example, if the equipment needs to be moved to a differ
`ent site, or to a repair facility, the trailer can simply be towed
`to the new site or facility without the need to first load the
`equipment onto a trailer or truck, which can be a difficult and
`hazardous endeavor. This is a clear benefit over other systems,
`wherein motors and pumps are attached to skids that are
`delivered to a site and placed on the ground.
`In order to provide a system wherein the pumps 110,
`motors 114, and VFDS 115 remain trailer mounted, certain
`improvements can be made to the trailers 112. For example, a
`third axle 146 can be added to increase the load capacity of the
`trailer and add stability. Additional Supports and cross mem
`bers 148 can be added to support the motors torque. In
`addition, the neck 149 of the trailer can be modified by adding
`an outer rib 150 to further strengthen the neck 149. The trailer
`can also include specially designed mounts 152 for the VFD
`115 that allow the trailer to move independently of the VFD
`115, as well as specially designed cable trays for running
`cables on the trailer 112. Although the VFD 115 is shown
`attached to the trailer in the embodiment of FIGS. 3 and 4, it
`could alternately be located elsewhere on the site, and not
`mounted to the trailer 112.
`In practice, a hydraulic fracturing operation can be carried
`out according to the following process. First, the water, sand,
`and other components are blended to form a fracturing fluid,
`which is pumped down the well by the electric-powered
`pumps. Typically, the well is designed so that the fracturing
`fluid can exit the wellbore at a desired location and pass into
`the Surrounding formation. For example, in Some embodi
`ments the wellbore can have perforations that allow the fluid
`to pass from the wellbore into the formation. In other embodi
`ments, the wellbore can include an openable sleeve, or the
`well can be open hole. The fracturing fluid can be pumped
`into the wellbore at a high enough pressur