(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2016/0105022 A1
`Oehring et al.
`(43) Pub. Date:
`Apr. 14, 2016
`
`US 20160105022A1
`
`(54)
`
`(71)
`
`(72)
`
`SYSTEMAND METHOD FOR PARALLEL
`POWER AND BLACKOUT PROTECTION FOR
`ELECTRIC POWERED HYDRAULC
`FRACTURING
`
`Applicant: US WELL SERVICES LLC, Houston,
`TX (US)
`Inventors: Jared Oehring, Houston, TX (US);
`Robert Kurtz, Houston, TX (US);
`Brennan Zaunbrecher, Houston, TX
`(US)
`
`(21)
`
`Appl. No.: 14/881,535
`
`(22)
`
`Filed:
`
`Oct. 13, 2015
`
`(60)
`
`Related U.S. Application Data
`Provisional application No. 62/063,680, filed on Oct.
`14, 2014.
`
`Publication Classification
`
`(51) Int. Cl.
`H02.3/00
`E2IB 43/26
`G05B 5/02
`E2IB 4I/00
`(52) U.S. Cl.
`CPC ............. H02.J.3/005 (2013.01); E2IB4I/0085
`(2013.01); E2IB 43/26 (2013.01); G05B 15/02
`(2013.01)
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`ABSTRACT
`(57)
`A system for powering equipment used in a hydraulic frac
`turing operation, the system including at least one first gen
`erator in electrical communication with a first Switchgear for
`providing power to primary components of a hydraulic frac
`turing operation, and at least one second generator in electri
`cal communication with a second Switchgear for providing
`power to backup components of a hydraulic fracturing opera
`tion. The at least one first generator is independent of the at
`least one second generator So that if the at least one first
`generator loses the ability to generate electricity, the at least
`one second generator can continue to generate electricity.
`
`
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`US 2016/01 05022 A1
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`Apr. 14, 2016
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`SYSTEMAND METHOD FOR PARALLEL
`POWER AND BLACKOUT PROTECTION FOR
`ELECTRIC POWERED HYDRAULC
`FRACTURING
`
`CROSS-REFERENCE to RELATED PATENT
`APPLICATIONS
`0001. This application is a continuation-in-part of non
`provisional U.S. patent application Ser. No. 13/679,.689, filed
`Nov. 16, 2012, and claims priority to U.S. Provisional Patent
`Applin. No. 62/063,680, filed Oct. 14, 2015, the full disclo
`sures of which are hereby incorporated herein by reference.
`
`BACKGROUND OF THE INVENTION
`0002 1. Field of the Invention
`0003. This technology relates to hydraulic fracturing in oil
`and gas wells. In particular, this technology relates to meth
`ods of powering electric hydraulic fracturing spreads.
`0004 2. Brief Description of Related Art
`0005 Typically, most equipment, including pumps used in
`hydraulic fracturing operations, are diesel powered, with
`each pump powered by a discrete diesel engine. If one pump
`goes out, the remaining pumps are unaffected, so that circu
`lation in the well can be maintained by the still-functioning
`pumps.
`0006. Some sites, however, utilize electric power to drive
`the pumps. In some Such systems, the entire power Supply
`may be routed through a single switchgear point. In such a
`system, all of the turbine generators are synced and tied
`together, which leads limited redundancy and blackout pro
`tection. In practice, this means that if one of the turbines loses
`power, there will not be sufficient remaining power to con
`tinue pumping operations. Thus, the entire system could
`cease to function, with negative consequences (e.g., a screen
`out) for the well. In addition, even in Systems where enough
`turbines remain serviceable to continue pumping the well to
`avoid a screen out, this function is not performed because the
`ability to shed load. Such as by shutting down power to non
`critical parts of the system, is limited. The power draw from
`all of the units overloads the turbines causing a shutdown of
`the entire system.
`
`SUMMARY OF THE INVENTION
`0007. One embodiment of the present technology pro
`vides a system for powering equipment used in a hydraulic
`fracturing operation. The system includes at least one first
`generator in electrical communication with a first Switchgear
`for providing power to primary components of a hydraulic
`fracturing operation, and at least one second generator in
`electrical communication with a second Switchgear for pro
`viding power to backup components of a hydraulic fracturing
`operation. The at least one first generatoris independent of the
`at least one second generator so that if the at least one first
`generator loses the ability to generate electricity, the at least
`one second generator can continue to generate electricity.
`0008. In some embodiments, the system can include a load
`shedding system for monitoring turbine generator overload.
`The loadshedding system can have a loadshed signal line that
`detects when a power draw will overload the system, and can
`be capable of shutting down electric power to a portion of the
`system to prevent an overload of the system. In some example
`embodiments, the load shedding system can include a
`
`breaker, and can be configured to send a signal to open the
`breaker to cut power to at least one of the primary or backup
`components.
`0009. In certain embodiments, the primary and secondary
`components can be selected from the group consisting of a
`pump, a data van, sand equipment, a blender, and a hydration
`unit. In addition, the loadshed signal line can carry a signal of
`4-20 mA to the breaker. Furthermore, the first and second
`Switchgear can channel electrical power from the at least one
`first generator and the at least one second generator, respec
`tively, to at least one transformer and/or to an auxiliary trans
`former. The at least one transformer can be connected to at
`least one pump, and the auxiliary transformer can be con
`nected to auxiliary equipment selected from the group con
`sisting of a data van, sand equipment, a blender, and a hydra
`tion unit.
`0010. Another embodiment of the present technology pro
`vides a system for preventing failure in a hydraulic fracturing
`system that includes at least one generator for transmitting
`power to a plurality of components of a hydraulic fracturing
`system, a loadshedding system for monitoring power draw of
`the plurality of components, the loadshedding system includ
`ing a load shed signal line, and a breaker configured for
`activation by the load shed signal line to cut power to one or
`more of the plurality of components if the one or more of the
`plurality of components draws more than a predetermined
`acceptable amount of power to prevent overload of the sys
`tem. In some embodiments, the plurality of components can
`be selected from the group consisting of a pump, a data Van,
`sand equipment, a blender, and a hydration unit. In addition,
`the load shed signal line can carry a signal of 4-20 mA to the
`breaker.
`0011 Yet another embodiment of the present technology
`provides a method for preventing failure of an electric pow
`ered hydraulic fracturing system. The method includes the
`steps of powering a plurality of primary components of a
`hydraulic fracturing operation by a first generator in electrical
`communication with the primary components through a first
`switchgear. The method further includes electrically connect
`inga plurality of backup components of a hydraulic fracturing
`operation to a second generator through a second Switchgear,
`and powering one or more of the plurality of backup compo
`nents in lieu of one or more of the plurality of primary com
`ponents in the event that power to the one or more of the
`plurality of primary components is lost. In some embodi
`ments, the method can also include the steps of determining
`when a power draw will overload one or more of the plurality
`of primary components in the hydraulic fracturing system,
`and sending a load signal to a breaker to cut power to the one
`or more of the plurality of primary components to prevent
`overloading of the hydraulic fracturing system.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`0012. The present technology will be better understood on
`reading the following detailed description of nonlimiting
`embodiments thereof, and on examining the accompanying
`drawing, in which:
`0013 FIG. 1 is a schematic plan view of equipment used in
`a hydraulic fracturing operation, according to an embodiment
`of the present technology;
`0014 FIG. 2 is a schematic plan view of equipment used in
`a hydraulic fracturing operation, according to an alternate
`embodiment of the present technology;
`
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`Apr. 14, 2016
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`0015 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
`0016 FIG. 4 is a right side view of the equipment and
`trailer shown in FIG. 3; and
`0017 FIG. 5 is diagram showing how components of the
`equipment can be divided into independent systems accord
`ing to an embodiment of the invention.
`
`DETAILED DESCRIPTION OF THE PREFERRED
`EMBODIMENT
`0.018. The foregoing aspects, features, and advantages of
`the present technology will be further appreciated when con
`sidered with reference to the following description of pre
`ferred embodiments and accompanying drawing, wherein
`like reference 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.
`0019 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, 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
`(although in Some embodiments, high pressure piping or hose
`can be used in place of the missile). 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 wellhead 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 equip
`ment are mounted directly to the truck.
`0020. In some embodiments, each electric motor 14 can be
`an induction motor, and can be capable of delivering about
`1500 horsepower (HP), 1750 HP, 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.
`0021. Each pump 10 can optionally be rated for about
`2250 horsepower (HP) or more. In addition, the components
`of the system, including the pumps 10 and the electric motors
`14, can be capable of operating during prolonged pumping
`operations, and intemperature in a range of about -20 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.
`0022. The VFDS 15 of the present technology can be dis
`crete to each vehicle 12 and/or pump 10. Such a feature is
`advantageous 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.
`0023 The electric motors 14 of the present technology can
`be designed to withstand an oilfield environment. Specifi
`cally, Some pumps 10 can have a maximum continuous power
`output 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.
`(0024. The VFD 15 can be designed to maximize the flex
`ibility, 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 Manufacturers Association (such as nema 1 pack
`aging), and power semiconductor heat sinks having one or
`more thermal sensors monitored by a microprocessor to pre
`vent semiconductor damage caused by excessive heat. Fur
`thermore, 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 interfaces. For example, motor diagnostics can be
`performed frequently (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 dis
`abled, if desired, when using, for example, a low impedance
`or high-speed electric motor.
`0025. 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 or
`stroke lengths 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 plung
`ers, and/or plungers having a ten (10) inch stroke.
`0026. 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
`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
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`skid can be advantageous because it enables quick transport
`of the equipment from place to place, and increased mobility
`of the pumping system.
`0027. Referring back to FIG. 1, also included in the equip
`ment is a plurality of electric generators 22 that are connected
`to, and provide power to, 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 converted into a gaseous form in a vaporizer prior to
`use in the generators. The use of natural gas to power the
`electric generators 22 can be advantageous because the units
`can run off of a pipeline supply to simplify fuel delivery and
`increase safety. Other embodiments allow use of natural gas
`stored in above ground natural gas vessels 24 already in place
`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 natu
`ral gas (LNG), compressed natural gas (CNG), diesel fuel, or
`a combination of these fuels.
`0028 FIG. 1 also shows equipment for transporting and
`combining 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.
`0029. In FIG. 1, there are specifically shown sand trans
`porting 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.
`0030. 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, 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 or more, and a 200 bbl steel hydration tank.
`0031) 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 down
`hole sensors and tools (not shown) to provide information to
`an operator, 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 console 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
`VFD fault indicator with a reset, a general fault indicator with
`a reset, a main estop, a programmable logic controller for
`local control, and a graphics panel. The graphics panel can
`include, for example, a touchscreen interface.
`0032 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. This is specifically due
`to the removal of the diesel engine and transmission. In the
`embodiment shown, the pumps 110 are powered by electric
`motors 114, which can also be mounted to the pump trailers
`112. Furthermore, 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.
`0033. The VFDs 115 shown in FIG. 2 can be discrete to
`each pump trailer 112 and/or pump 110. Such a feature is
`advantageous 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.
`0034. In addition to the above, and still referring to FIG. 2,
`the system 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 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.
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`0035. The pumps 110 are fluidly connected to a wellhead
`116 via a missile 118. As shown, the pump trailers 112 can be
`positioned near enough to the missile 118 to connect fractur
`ing fluid lines 120 between the pumps 110 and the missile
`118. The missile 118, or other fluid connection device, such as
`high pressure piping or hose, is then connected to the well
`head 116 and configured to deliver fracturing fluid provided
`by the pumps 110 to the wellhead 116.
`0036. This embodiment also includes a plurality of turbine
`generators 122 that are connected to, and provide power to,
`the electric motors 114 on the pump trailers 112. To accom
`plish this, the turbine generators 122 can be connected to the
`electric 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.
`0037. The embodiment of FIG. 2 can include other equip
`ment 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.
`0038. 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
`advantageous over known systems for many different rea
`sons. For example, the equipment (e.g. pumps, electric
`motors, and generators) is lighter than the diesel pumps com
`monly used in the industry. The lighter weight of the equip
`ment 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. Further
`more, and as shown in FIGS. 3 and 4, trailers 112 can be used
`to transport 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 engine and transmissions that are replaced
`by a motor.
`0039. The ability to transfer the equipment of the present
`technology directly on a truck body or two to a trailer
`increases efficiency and lowers cost. In addition, by eliminat
`ing 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.
`0040. 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 provides advantages such as increased mobility of
`the system. For example, if the equipment needs to be moved
`to a different 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.
`0041. 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.
`0042. 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 elec
`tric-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 embodiments the wellbore can have perforations that
`allow the fluid to pass from the wellbore into the formation. In
`other embodiments, 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 pressure that
`the fracturing fluid cracks the formation, and enters into the
`cracks. Once inside the cracks, the sand, or other proppants in
`the mixture, wedges in the cracks, and holds the cracks open.
`In some embodiments, a fluid other than water can be used to
`the proppant.
`0043. Using the pump control and data monitoring equip
`ment 40,140 the operator can monitor, gauge, and manipulate
`parameters of the operation, Such as pressures, and Volumes
`of fluids and proppants entering and exiting the well. For
`example, the operator can increase or decrease the ratio of
`sand to water as the fracturing process progresses and circum
`stances change.
`0044) This process of injecting fracturing fluid into the
`wellbore can be carried out continuously, or repeated multiple
`times in stages, until the fracturing of the formation is opti
`mized. Optionally, the wellbore can be temporarily plugged
`between each stage to maintain pressure, and increase frac
`turing in the formation. Generally, the proppant is inserted
`into the cracks formed in the formation by the fracturing, and
`
`LIBERTY EXHIBIT 1014, Page 10
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`US 2016/01 05022 A1
`
`Apr. 14, 2016
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`left in place in the formation to prop open the cracks and allow
`oil or gas to flow into the wellbore.
`0045. In FIG. 5 there is shown an embodiment of the
`invention wherein a plurality of generators 222A, 222B are
`divided into separate, parallel, and independent groups,
`including group A and group B. Each group A, B of genera
`tors 222A, 222B is connected in turn to separate and distinct
`groups of transformers 223A, 223B and pumps 210A, 210B.
`as well as separate and distinct auxiliary trailers 225A, 225B,
`each including its own ancillary equipment, such as, for
`example, data vans 227A, 227B, sand equipment 229A,
`229B, blenders 234A,234B, and hydration units 232A, 232B.
`Although FIG. 5 shows more than one generator 222A, 222B
`in each group A, B, it is possible that any individual group
`could include a single generator 222A, 222B. Furthermore,
`although not shown in FIG. 5, multiple gas compressors can
`be utilized to supply fuel to the generators 222A, 222B so that
`there is redundancy in the gas compression portion of the
`system as well.
`0046. The advantages prov