( 19 ) United States
`( 12 ) Patent Application Publication ( 10 ) Pub . No .: US 2020/0040705 A1
`Feb. 6 , 2020
`( 43 ) Pub . Date :
`Morris et al .
`
`US 20200040705A1
`
`IN
`
`( 54 ) SWITCH GEAR TRANSPORT THAT
`DISTRIBUTES ELECTRIC POWER FOR
`FRACTURING OPERATIONS
`( 71 ) Applicant : Typhon Technology Solutions , LLC ,
`The Woodlands , TX ( US )
`( 72 ) Inventors : Jeffrey G. Morris , The Woodlands , TX
`( US ) ; Adrian Benjamin Bodishbaugh ,
`Fayetteville , AK ( US )
`( 21 ) Appl . No .: 16 / 521,460
`( 22 ) Filed :
`Jul . 24 , 2019
`Related U.S. Application Data
`( 60 ) Provisional application No. 62 / 713,393 , filed on Aug.
`1 , 2018 .
`
`Publication Classification
`
`( 51 ) Int . Ci .
`E21B 41/00
`HO2B 5/00
`
`( 2006.01 )
`( 2006.01 )
`
`( 2006.01 )
`( 2006.01 )
`
`HO2J 9/00
`E21B 43/26
`( 52 ) U.S. Ci .
`E21B 41/00 ( 2013.01 ) ; E21B 43/26
`CPC
`( 2013.01 ) ; H02J 9/00 ( 2013.01 ) ; HO2B 5/00
`( 2013.01 )
`
`( 57 )
`
`ABSTRACT
`
`A system and a method for distributing electric power from
`a power source of electricity to power fracturing operations
`includes a plurality of circuit breakers , each circuit breaker
`including a first circuit breaker connector and a second
`circuit breaker connector , each of which outputs electric
`power to a corresponding transport at a first voltage level , a
`power source connector that receives electric power from a
`power source of electricity at the first voltage level , and a
`black start generator that generates electric power at a
`second voltage level and that supplies the generated electric
`power to start the power source of electricity .
`
`
`
`
`
`AUXILIARY POWER 120
`
`48
`
`MOBILE SOURCE OF ELECTRICITY
`47 1:46
`
`30
`
`12
`
`108
`40 42
`
`FRAC TANK
`
`CHEMICALS
`
`SAND STORAGE
`
`102
`
`13,800 V - 4,160 V TRANSFORMER
`13,800 V -- 480 V TRANSFORMER
`13,800 V
`480 V
`
`X
`
`1
`
`1
`
`104
`
`TET 104
`
`0 :
`
`110 112
`
`110 112
`
`110 112
`
`110
`
`112
`
`110 112
`
`??? ??
`
`sou Marehe 104 ani
`Tio 12
`
`WELL SITE 100
`
`WELL HEAD
`101
`
`103
`
`44
`
`345
`
`901
`
`
`
`SAND CONVEYOR
`
`LIBERTY EXHIBIT 1004, Page 1
`
`

`

`Patent Application Publication
`
`Feb. 6 , 2020 Sheet 1 of 5
`
`US 2020/0040705 A1
`
`
`
`WELL HEAD 101
`
`103
`
`FIG.1
`
`
`
`
`
`WELL SITE 100
`
`114
`
`- 480 V TRANSFORMER
`13,800 V – 4,160 V TRANSFORMER
`13,800 V
`
`104 0 : 1
`
`13,800 V 480 V
`
`104 10 :
`
`104 = :
`
`104 h
`
`U
`
`0 :
`
`X
`
`14
`
`*
`
`104
`
`104
`
`102
`
`110 112
`
`?O Ti2
`
`110 112
`
`110 112
`
`*
`
`110 112
`
`110 112
`
`44
`
`114
`
`1.45
`
`40 42
`
`108
`
`
`
`MOBILE SOURCE OF ELECTRICITY
`
`474 12 46
`
`X
`
`112
`
`30
`?
`48
`
`
`AUXILIARY POWER
`
`120
`
`901
`
`CONVEYOR
`
`SAND
`
`
`
`FRAC TANK
`
`CHEMICALS
`
`
`
`SAND STORAGE
`
`LIBERTY EXHIBIT 1004, Page 2
`
`

`

`Patent Application Publication
`
`Feb. 6 , 2020 Sheet 2 of 5
`
`US 2020/0040705 A1
`
`222
`
`210
`
`209
`
`208
`
`209
`
`220
`
`
`
`
`
`2023 2024 2021 2022 202K 202L
`
`
`
`
`
`
`
`204A
`
`204B
`
`206A
`
`
`
`
`
`2024 2023 2020 202D 2025 202F
`
`
`
`
`
`
`
`200
`
`
`
`
`
`2120 212P 2125 2127 212W 212X
`
`
`
`
`
`
`
`FIG . 2
`
`
`
`
`
`212M 212N 120 212R 2120 212V
`
`
`
`
`
`
`QOQOT 206B
`Q0O
`QOQO
`
`2121 212 )
`
`
`
`
`
`212C 212D 212K 212L 2126 212H
`
`212E 212F
`
`( 212E
`
`
`
`212A 212B
`
`LIBERTY EXHIBIT 1004, Page 3
`
`

`

`Patent Application Publication
`
`Feb. 6 , 2020 Sheet 3 of 5
`
`US 2020/0040705 A1
`
`210
`
`www
`
`209
`
`208
`
`209
`
`204A
`
`204B
`
`206A
`
`
`
`
`
`2021 2025 2024
`
`
`
`2120 212V
`
`FIG . 3
`
`
`
`
`
`
`
`
`
`
`
`2120 212D 2127 212H 212K 212L 2120 212P 2125 2121 2 12W 212X
`
`
`
`
`212A 212B 212E 212F 2121 212 ) ] 212M 212N ] 2120 2122 2120
`
`
`
`
`
`
`QOQOT 206B
`
`QQ0d
`
`OC
`
`
`
`2027 2026 202H 2021
`
`
`
`
`
`202E
`202D
`
`
`
`
`
`202A 202B 202C
`
`300
`
`LIBERTY EXHIBIT 1004, Page 4
`
`

`

`Patent Application Publication
`
`Feb. 6 , 2020 Sheet 4 of 5
`
`US 2020/0040705 A1
`
`CIRCUIT
`CIRCUIT
`CIRCUIT
`CIRCUIT
`CIRCUIT
`CIRCUIT
`CIRCUIT
`CIRCUIT
`CIRCUIT
`CIRCUIT
`CIRCUIT
`CIRCUIT
`
`BREAKER 202L
`BREAKER 202K
`BREAKER 202 ]
`BREAKER
`2021
`BREAKER 202H
`BREAKER 2026
`BREAKER 202F
`BREAKER 202E
`BREAKER 202D
`BREAKER 2020
`BREAKER
`202B
`BREAKER 202A
`
`
`
`POWER SOURCE
`
`CONNECTION 204B
`
`
`
`POWER SOURCE
`
`CONNECTION 204A
`
`402
`
`400
`
`
`
`
`
`
`
`
`
`
`
`
`
`212K2124 212M 212N 2120 212P 2120 212R 2125 2127 2120 212V 212W 212X
`
`
`
`
`
`
`
`
`
`
`
`
`
`FIG . 4
`
`
`
`
`
`
`
`
`
`212A 212B 2120 2120 2126 2127 2126 2124 2121 212 )
`
`
`
`
`
`
`
`
`
`LIBERTY EXHIBIT 1004, Page 5
`
`

`

`Patent Application Publication
`
`Feb. 6 , 2020 Sheet 5 of 5
`
`US 2020/0040705 A1
`
`500
`
`u START
`
`GENERATE ELECTRIC POWER TO START ONE OR MORE POWER SOURCES OF
`ELECTRICITY
`
`RECEIVE ELECTRIC POWER FROM THE POWER SOURCES OF ELECTRICITY AFTER
`STARTING THE POWER SOURCES OF ELECTRICITY
`
`DISTRIBUTE ELECTRIC POWER TO ONE OR MORE CIRCUIT BREAKERS
`
`OUTPUT ELECTRIC POWER TO MULTIPLE TRANSPORTS SUCH THAT ONE OF THE
`CIRCUIT BREAKERS PROVIDES ELECTRIC POWER TO AT LEAST TWO TRANSPORTS
`
`502
`
`504
`
`506
`
`508
`
`END
`
`FIG . 5
`
`LIBERTY EXHIBIT 1004, Page 6
`
`

`

`US 2020/0040705 A1
`
`Feb. 6 , 2020
`
`SWITCH GEAR TRANSPORT THAT
`DISTRIBUTES ELECTRIC POWER FOR
`FRACTURING OPERATIONS
`
`CROSS - REFERENCE TO RELATED
`APPLICATIONS
`This application claims the benefit of U.S. Prov .
`[ 0001 ]
`Appl . No. 62 / 713,393 filed 1 Aug. 2018 , which is incorpo
`rated herein by reference .
`BACKGROUND
`[ 0002 ] Hydraulic fracturing has been commonly used by
`the oil and gas industry to stimulate production of hydro
`carbon producing wells , such as oil and / or gas wells .
`Hydraulic fracturing , sometimes called “ fracing ” or “ frack
`ing ” is the process of injecting fracturing fluid into a
`wellbore to fracture the subsurface geological formations
`and release hydrocarbons . The fracturing fluid is pumped
`into a wellbore at a pressure sufficient to cause fissures
`within the underground geological formations . Once inside
`the wellbore , the fracturing fluid fractures the underground
`formation . The fracturing fluid may include water , various
`chemical additives , and proppants that promote the extrac
`tion of the hydrocarbon reserves , such as oil and / or gas .
`Proppants , such as fracturing sand , prevent fissures and
`fractures in the underground formation from
`closing ;
`thereby , allowing the formation to remain open so that
`hydrocarbons flow through the hydrocarbon wells .
`[ 0003 ] Implementing fracturing operations at well sites
`requires extensive investment in equipment , labor , and fuel .
`A typical fracturing operation uses fracturing equipment ,
`personnel to operate and maintain the fracturing equipment ,
`large amounts of fuel to power the fracturing operations , and
`relatively large volumes of fracturing fluids . As such , plan
`ning for fracturing operations is complex and encompasses
`a variety of logistical challenges that include minimizing the
`on - site area or “ footprint ” of the fracturing operations ,
`providing adequate power and / or fuel to continuously power
`the fracturing operations , increasing the efficiency of the
`hydraulic fracturing equipment , and reducing the environ
`mental impact resulting from fracturing operations . Thus ,
`numerous innovations and improvements of existing frac
`turing technology are needed to address the variety of
`complex and logistical challenges faced in today's fracturing
`operations .
`
`SUMMARY
`[ 0004 ] The following presents a simplified summary of the
`disclosed subject matter in order to provide a basic under
`standing of some aspects of the subject matter disclosed
`herein . This summary is not an exhaustive overview of the
`technology disclosed herein , and it is not intended to identify
`key or critical elements of the invention or to delineate the
`scope of the invention . Its sole purpose is to present concepts
`in a simplified form as a prelude to the more detailed
`description that is discussed later .
`[ 0005 ]
`In one embodiment , a switch gear transport is
`provided which comprises : a plurality of circuit breakers ,
`wherein each circuit breaker includes a first circuit breaker
`connector and a second circuit breaker connector , wherein
`each of the first circuit breaker connector and the second
`circuit breaker connector is configured to output electric
`power to a corresponding transport at a first voltage level ; a
`
`power source connector that is configured to receive electric
`power from a power source of electricity at the first voltage
`level ; and a black start generator that generates electric
`power at a second voltage level and that is configured to
`supply the generated electric power at the second voltage
`level to start a power source of electricity
`[ 0006 ] In another embodiment , an electric fracturing sys
`tem powered by a power source of electricity is provided
`which comprises : a switch gear transport that is configured
`to : ( i ) electrically connect to the power source of electricity ,
`( ii ) receive electric power from the power source of elec
`tricity at a first voltage level , and ( iii ) provide the received
`electric power to one or more transports at the first voltage
`level ; a fracturing pump transport that is electrically con
`nected to the switch gear transport via an electrical cable and
`that receives the electric power at the first voltage level via
`the electrical cable ; and a circuit breaker connector that is
`disposed on the switch gear transport and that supplies the
`electric power at the first voltage level to the fracturing
`pump transport via the electrical cable , wherein the fractur
`ing pump transport comprises a transformer that steps down
`the electric power received at the first voltage level to at least
`one lower voltage level .
`[ 0007 ]
`In yet another embodiment , a method for distrib
`uting electric power from a mobile source of electricity to
`power fracturing operations is provided which comprises :
`receiving , at a transport , electric power from the mobile
`source of electricity at a first voltage level , wherein the first
`voltage level falls within a range of 1,000 V to 35 kilovolts ;
`supplying , from the transport , the electric power to a frac
`turing pump transport at the first voltage level using only a
`first , single cable connection , and supplying , from the trans
`port , the electric power to a second transport at the first
`voltage level using only a second , single cable connection .
`[ 0008 ]
`In yet another embodiment , each of the above
`described embodiments and variations thereof , may be
`implemented as a method , apparatus , and / or system .
`BRIEF DESCRIPTION OF THE DRAWINGS
`[ 0009 ] For a more complete understanding of this disclo
`sure , reference is now made to the following brief descrip
`tion , taken in connection with the accompanying drawings
`and detailed description , wherein like reference numerals
`represent like parts .
`[ 0010 ]
`FIG . 1 is a schematic diagram of an embodiment of
`a medium voltage power distribution system for a fracturing
`fleet located at well site .
`[ 0011 ]
`FIG . 2 is a schematic diagram of an embodiment of
`a switch gear transport .
`[ 0012 ] FIG . 3 is a schematic diagram of another embodi
`ment of a switch gear transport .
`[ 0013 ] FIG . 4 is a block diagram of an embodiment of the
`power system for a switch gear transport .
`[ 0014 ] FIG . 5 is a flow chart of an embodiment of a
`method to manage and distribute electric power for a switch
`gear transport .
`[ 0015 ] While certain embodiments will be described in
`connection with the illustrative embodiments shown herein ,
`the invention is not limited to those embodiments . On the
`contrary , all alternatives , modifications , and equivalents are
`included within the spirit and scope of the invention as
`defined by the claims . In the drawing figures , which are not
`to scale , the same reference numerals are used throughout
`the description and in the drawing figures for components
`
`LIBERTY EXHIBIT 1004, Page 7
`
`

`

`US 2020/0040705 A1
`
`2
`
`Feb. 6 , 2020
`
`and elements having the same structure , and primed refer
`ence numerals are used for components and elements having
`a similar function and construction to those components and
`elements having the same unprimed reference numerals .
`DETAILED DESCRIPTION
`[ 0016 ] As used herein , the term “ transport ” refers to any
`transportation assembly , including , but not limited to , a
`trailer , truck , skid , rail car , and / or barge used to transport
`relatively heavy structures and / or other types of articles ,
`such as fracturing equipment and fracturing sand . A trans
`port could be independently movable from another trans
`port . For example , a first transport can be mounted or
`connected to a motorized vehicle that independently moves
`the first transport while an unconnected second transport
`remains stationary .
`[ 0017 ] As used herein , the term “ trailer ” refers to a trans
`portation assembly used to transport relatively heavy struc
`tures and / or other types of articles ( such as fracturing
`equipment and fracturing sand ) that can be attached and / or
`detached from a transportation vehicle used to pull or tow
`the trailer . As an example , the transportation vehicle is able
`to independently move and tow a first trailer while an
`unconnected second trailer remains stationary . In one or
`more embodiments , the trailer includes mounts and mani
`fold systems to connect the trailer to other fracturing equip
`ment within a fracturing fleet or fleet . The term “ lay - down
`trailer ” refers to a specific embodiment of a trailer that
`includes two sections with different vertical heights . One of
`the sections or the upper section is positioned at or above the
`trailer axles and another section or the lower section is
`positioned at or below the trailer axles . In one embodiment ,
`the main trailer beams of the lay - down trailer may be resting
`on the ground when in operational mode and / or when
`uncoupled from a transportation vehicle , such as a tractor .
`[ 0018 ] As used herein , the term “ low voltage ” refers to a
`voltage range from about 50 volts ( V ) to 1,000 V for
`alternating current ( AC ) electric power . The term “ medium
`voltage ” refers to a voltage range from about 1,000 V to
`about 35 kilovolts ( kV ) for AC electric power , and the term
`“ high voltage ” refers to a voltage range greater than 35 kV
`for AC electric power . Although the terms “ low voltage , ”
`" medium voltage , " and " high voltage " generally refer to
`voltage ranges in AC electric power , the disclosure is not
`limited to AC electric power and could also utilize current
`( DC ) voltage .
`[ 0019 ] Unless otherwise specified within the disclosure ,
`the term " electrical connection ” refers to connecting one
`transport to another transport using one or more electrical
`cables . The term “ electrical cable ” can be interchanged
`throughout this disclosure with the term “ power cable ”
`“ power cable connection , " " cable connection , ” or “ electrical
`cable connection . ” The terms “ electrical cable , " " power
`cable ” “ power cable connection , " " cable connection , ” and
`“ electrical cable connection ” refer to a single cable assembly
`that bundles together one or more wires ( e.g. , copper wires )
`that carry AC or DC electric current to provide electric
`power . In one or more embodiments , the single cable
`assembly also includes other wire types , such as fiber optic
`wires that perform other functions besides providing electric
`power . For example , the fiber optic wires are able to carry
`light for the purposes of transferring communication signals .
`[ 0020 ]
`Various example embodiments are disclosed herein
`that distribute electric power using a switch gear transport to
`
`power one or more fracturing fleets . For example , FIG . 1 is
`a schematic diagram of an embodiment of a medium voltage
`power distribution system for a fracturing fleet 103 located
`at well site 100. As shown in the present example , the system
`includes a switch gear transport 108 in electrical communi
`cation with one or more power sources of electricity 102 ,
`120 , such as mobile source 102 via a first connection 46 and
`an auxiliary source 120 via a second connection 48. In turn ,
`the switch gear transport 108 is in electrical communication
`with one or more power consumers , such as fracturing pump
`transports 104 via connections 44 and a blender - hydration
`transport 106 via connection 45 .
`[ 0021 ] The switch gear transport 108 may include a black
`start generator 30 that provides electric power to initiate and
`start at least one of the one or more power sources of
`electricity . Once the power sources of electricity are opera
`tional , the switch gear transport 108 receives electric power
`from the power sources 102 , 120 of electricity at a desig
`nated input voltage level and outputs the electric power to
`the power consumers . In one or more embodiments , the
`designated input voltage level is a relatively high medium
`voltage level , such as 13.8 kilovolts ( kV ) . ( Although the
`voltage and current levels referenced in FIG . 1 generally
`refer to AC electric power , other embodiments could have
`the fracturing fleet 103 adapted to be powered using DC
`electric power . ) The switch gear transport 108 maintains the
`input voltage level when outputting electric power to one or
`more transports , such as fracturing pump transports 104 and
`a hydration - blender transport 106 .
`[ 0022 ]
`To output and provide electric power , each circuit
`breaker 40 includes a circuit breaker connector 42 that
`connects to a transport ( e.g. , fracturing pump transport )
`using a single electrical cable 44. For example , a circuit
`breaker connector 42 may connect to a fracturing pump
`transport 104 using a single electrical cable 44 that supplies
`electric power at a target output voltage level of about 13.8
`kV . To provide additional redundancy and / or to power
`additional fracturing fleets , each circuit breaker 40 could
`include more than one circuit breaker connector 42. When
`the transports 104 , 106 receive the electric power at the
`target output voltage level , each of the transports 104 , 106
`include one or more transformers 110 , 112 , 114 that step
`down the target output voltage level ( e.g. , 13.8 kV ) . The
`transformers 110 , 112 , 114 are able step down the target
`output voltage level to one or more lower voltage levels that
`fracturing equipment ( e.g. , electric prime movers ) mounted
`on the transports 104 , 108 may utilize . As an example , a
`transformer 110 , 112 mounted on the fracturing pump trans
`port is able to step down electric power received at the target
`output voltage level ( e.g. , 13.8 kV ) to lower voltage levels
`( e.g. , 4.2 kV , 2.1 kV , 600 volts ( V ) , 480 V , 240 V , and 120
`V ) .
`[ 0023 ] As shown in FIG . 1 , the power source of electricity
`102 provides power by con onnecting to the switch gear trans
`port 108 using six medium voltage ( e.g. , 13.8 kV ) cable
`connections 44. In one or more embodiments , the power
`source of electricity 102 includes one or more turbine
`electric generator transports that compress and mix com
`bustion air with hydrocarbon fuel to spin and generate
`mechanical energy and then converts the mechanical energy
`to electricity . The power source of electricity 102 could also
`include an inlet and exhaust transport that provides venti
`lation and combustion air to the turbine - electric generator
`transport when generating electricity . Configuring and uti
`
`LIBERTY EXHIBIT 1004, Page 8
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`

`

`US 2020/0040705 A1
`
`3
`
`Feb. 6 , 2020
`
`lizing a turbine - electric generator transport and an inlet and
`exhaust transport are discussed and shown in more detail in
`U.S. Pat . No. 9,534,473 , filed Dec. 16 , 2015 by Jeffrey G.
`Morris et al . and entitled “ Mobile Electric Power Generation
`for Hydration Fracturing of Subsurface Geological Forma
`tions , ” which is hereby incorporated by reference as if
`reproduced in its entirety . In other embodiments , the power
`source of electricity 102 could include other transport con
`figurations to employ a centralized source of electricity that
`powers fracturing equipment .
`[ 0024 ] FIG . 1 also illustrates that the switch gear transport
`108 connects to an auxiliary power transport 120 with one
`medium voltage ( e.g. , 13.8 kV ) cable connection 48. The
`auxiliary power transport 120 provides ancillary power for
`situations where the power source of electricity 102 is out of
`service or where peak electric power demand exceeds the
`electric power output of the power source of electricity 102 .
`[ 0025 ] The switch gear transport 108 also includes a
`transformer 112 that steps down electric power received at
`a medium voltage level ( e.g. , 13.8 kV ) from the auxiliary
`power transport 120 and / or power source of electricity 102
`to a low voltage level ( e.g. , 480 V , 240 V and 110 V ) . In one
`or more embodiments , the low voltage level ( e.g. , 480 V )
`connection may provide electric power to ignite or start the
`power source of electricity 102 and / or provide power to
`other fracturing equipment .
`[ 0026 ]
`In one or more embodiments , the switch gear
`transport 108 may house a black start generator 30 to initiate
`and start the power source of electricity 102. Using FIG . 1
`as an example , the black start generator 30 may provide
`electric power at 480 V. When the black start generator 30
`generates electric power , the switch gear transport 108
`supplies the electric power directly to the power source of
`electricity 102 using the low voltage level connection 47. In
`other examples , the black start generator 30 may provide
`electric power at voltage levels that exceed 480 V ( e.g. , 600
`V , 2.1 kV , and 4.2 kV ) . In this situation , the switch gear
`transport 108 could include other transformers ( 112 ) to step
`down voltage from the black start generator 30 to a voltage
`level to start the power source of electricity 102 .
`[ 0027 ] As shown in FIG . 1 , the switch gear transport 108
`outputs and supplies medium voltage ( e.g. , 13.8 kV ) with
`cable connections 45 , 44 directly to the hydration - blender
`transport 106 and the fracturing pump transport 104 without
`connecting to any intermediate transports . FIG . 1 depicts
`that the switch gear transport 108 generates a total of seven
`medium voltage ( e.g. , 13.8 kV ) cable connections 44 , 45 ,
`where each fracturing pump transport 104 is directly con
`nected to the switch gear transport 108 with a single medium
`voltage ( e.g. , 13.8 kV ) cable connection 44. The switch gear
`transport 108 also directly connects to the hydration - blender
`transport 106 using a single medium voltage ( e.g. , 13.8 kV )
`cable connection 45. Additional transports can be connected
`to the switch gear transport 108 with a single medium
`voltage ( e.g. , 13.8 kV ) cable connection , for example , up to
`a total of 24 for a single switch gear transport 108 .
`[ 0028 ] The medium voltage power distribution system
`shown in FIG . 1 is able to reduce the number of electrical
`cables used to supply electric power to the fracturing pump
`transport 104 and hydration - blender transport 106 when
`compared to other power distribution systems that provide
`power to the different transports at lower voltage levels ( e.g. ,
`4.2 kV , 600 V , and 480 V ) . As shown in FIG . 1 , for instance ,
`the fracturing fleet 103 reduces the number of electrical
`
`cables to one electrical cable 44 for each fracturing pump
`transport 104. A further reduction of electrical cables is
`shown by supplying one electrical cable 45 to the hydration
`blender transport 106 instead of multiple electrical cables
`used to power a blender transport and a hydration transport .
`[ 0029 ] One reason the medium voltage power distribution
`system is able to utilize less electrical cables is that each
`electrical cable 44 , 45 does not need to supply a relatively
`high current ( e.g. , equal to or more than 600 A ) to each
`fracturing pump transport 104 and hydration - blender trans
`port 106. Supplying electric power at relatively lower cur
`rent levels avoids the safety concerns and / or connection /
`disconnection issues associated with using a single electrical
`cable that supplies relatively high current ( e.g. , at 600 A ) ;
`thereby , reducing the risk of harm and physical injuries to
`operators .
`[ 0030 ] Each fracturing pump transport 104 may include
`one or more transformers 110 , 112 to step down the voltage
`received from the switch gear transport 108 to different
`voltage levels . Using FIG . 1 as an example , each fracturing
`pump transport 104 may include two separate and indepen
`dent transformers , a first transformer 110 to step down to a
`voltage level of 4.2 kV or 2.1 kV and a second transformer
`112 to step down to a voltage level of 480 V , 240 V and 110
`V.
`[ 0031 ]
`In other examples , each fracturing pump transport
`104 could include a single transformer 110 that produces
`multiple voltages levels . For example , the fracturing pump
`transport 104 may mount a three phase or three winding
`transformer 110 to step down the voltage to two different
`voltage levels . The 4.2 kV or 2.1 kV voltage level supplies
`electric power to one or more electric prime movers ( not
`shown ) that drive one or more pumps ( not shown ) and the
`480 V , 240 V and 110 V supplies electric power to the drives
`and / or other control instrumentation mounted on the frac
`turing pump transport 104. Transformers 110 and 112 are
`able to supply enough electric current to power the prime
`movers , drivers , and / or other control instrumentation .
`[ 0032 ] FIG . 1 also illustrates that the hydration - blender
`transport 106 includes a transformer 114 that steps down the
`voltage levels to 480 V , 240 V and 110 V. The hydration
`blender transport 106 can use the stepped down voltages
`levels to provide electric power to the electric prime movers ,
`drives , and / or other control instrumentation mounted on the
`hydration - blender transport 106. The hydration - blender
`transport 106 may also be configured to provide electric
`power at the 480 V , 240 V and 110 V voltage levels to other
`downstream fracturing equipment , such as the sand con
`veyor .
`[ 0033 ] The medium voltage power distribution system
`may utilize one or more electrical connections to provide
`electric power to the sand conveyor , data van 114 and / or
`other fracturing equipment that utilize electric power .
`Although FIG . 1 illustrates that switch gear transport 108
`provides electric power to the hydration - blender transport
`106 , other embodiments could have the switch gear trans
`port 108 separately connect to a hydration transport and a
`blender transport . In such an embodiment , the switch gear
`transport 108 may connect to the hydration transport using
`a single medium voltage ( e.g. , 13.8 kV ) cable connection
`and another single medium voltage ( e.g. , 13.8 kV ) cable
`connection to connect to the blender transport .
`[ 0034 ] By mounting the drives and transformers 110 and /
`or 112 onto the fracturing pump transport 104 and the
`
`LIBERTY EXHIBIT 1004, Page 9
`
`

`

`US 2020/0040705 A1
`
`4
`
`Feb. 6 , 2020
`
`transformer 114 on the hydration - blender transport 106 , the
`transports 104 , 106 become individually autonomous by
`removing the need for other separate support - based trailers ,
`such as the auxiliary unit transport and drive power trans
`ports that provide power conversion and / or drive control .
`Having autonomous trailers allows the fracturing fleet 103 to
`become scalable and flexible , where each fracturing pump
`transport may be interchangeable with each other and allow
`for a reduced physical foot print of the fracturing fleet 103 .
`For example , if the well is relatively small , the fracturing
`fleet 103 may have a reduced number of fracturing pump
`transports 104 ( e.g. , four transports instead of six trans
`ports ) . Conversely , if the well is large , more fracturing pump
`transports 104 can be stacked to increase pumping capacity
`without utilizing additional support - based transports .
`[ 0035 ]
`In FIG . 1 , the switch gear transport 108 receives
`electricity generated from the power source of electricity
`102 at an input voltage level ( e.g. , 13.8 kV ) . After receiving
`the electric power , the switch gear transport 108 utilizes
`multiple circuit breakers 40 to distribute the electric power
`to one or more transports , such as fracturing pump transport
`104 and hydration - blender transport 106. Each circuit
`breaker 40 could include electrical disconnects , switches ,
`fuses , and / or circuit protectors to protect other fracturing
`equipment of fracturing fleet 103 .
`[ 0036 ]
`In one embodiment , the circuit breakers 40 are
`constructed to produce a target output voltage level that is
`about the same as the input voltage level . Each circuit
`breaker 40 may have a maximum current rating that is about
`equal to or exceeds a maximum current rated for powering
`one or more transports at the target output voltage level . For
`example , a circuit breaker 40 that provides electric power to
`two fracturing pump transports 104 can have a maximum
`current rating of about 500 A when each fracturing pump
`transport 104 is expected to utilize a maximum current of
`250 A. In other words , the circuit breaker 40 can implement
`a 2 : 1 ratio regarding the number of fracturing pump trans
`ports 104 that receive electric power from the circuit breaker
`40. Other embodiments could have different ratios where the
`circuit breaker provides electric power to a single transport
`( e.g. , 1 : 1 ratio ) or more than two transports ( e.g. , 3 : 1 or 4 : 1
`ratio ) . The switch gear transport 108 is discussed in more
`detail with reference to FIGS . 2 and 3 .
`[ 0037 ] The switch gear transport 108 could also be setup
`to act as a hub for receiving control and monitoring infor
`mation for fracturing fleet 103. Recall that cable connections
`44 , 45 could include fiber optics wires that allows the switch
`gear transport 108 to communicate , monitor , and provide
`control signals to other transports , such as fracturing pump
`transport 104 and hydration - blender transport 106. Specifi
`cally , the switch gear transport 108 could house control and
`monitoring equipment to communicate with other transports
`and fracturing equipment . For example , the switch gear
`transport 108 could include fiber optics , network translation
`tables , power measurements ( e.g. , voltage and current ) and
`power management equipment ( e.g. , safety circuits and
`safety logic ) . The switch gear transport 108 could also
`provide data received from transports and fracturing equip
`ment to data van 114. The data van 114 remotely controls the
`switch gear transport 108 .
`[ 0038 ] Although FIG . 1 illustrates a specific embodiment
`of a fracturing fleet 103 that utilizes electric power for
`operations , the disclosure is not limited to these particular
`embodiments . For instance , with reference to FIG . 1 , the
`
`disclosure describes a switch gear transport 108 receiving
`electric power from a centralized power source of electricity
`102 located at the well site 100. However , other embodi
`ments could have the switch gear transport 108 receive
`electric power from other types of power sources , such as a
`power grid or a stationary power source . Additionally or
`alternatively , the fracturing fleet 103 shown in FIG . 1 may
`utilize a separate hydration transport and blender transport
`instead of a combined hydration - blender transport 106 .
`Although not explicitly shown in FIG . 1 , the switch gear
`transport 108 may also be able to power a second fracturing
`fleet located at an adjacent well site or for the purposes of
`fracturing multiple well heads 101. The use and discussion
`of FIG . 1 is only an example to facilitate ease of description
`and explanation .
`[ 0039 ] FIG . 2 is a schematic diagram of an embodiment of
`a switch gear transport 200 , such as the switch gear transport
`108 shown in FIG . 1. As shown in the side - profile view , the
`switch gear transport 200 includes circuit breakers 202A - L ,
`power source connections 204A and 204B , auxiliary power
`source connections 206A and 206B , power system 208 , and
`black start generator 210. Within each of the circuit breakers
`202A - L are circuit breaker connectors 212A - X that output
`and provide electric power to transports , such as a fracturing
`pump transport ( 104 ) .
`[ 0040 ] Each circuit breaker 202 may include multiple
`circuit breaker connectors 212 ( e.g. , two circuit breaker
`connectors 212 ) . Using FIG . 2 as an example , circuit breaker
`202A includes circuit breaker connectors 212A and 212B ;
`circuit breaker 202B includes circuit breaker connectors
`212C and 212D ; circuit breaker 202C includes circuit
`breaker connectors 212E and 212F and so