Power sources and transmission networks for auxiliary equipment onboard hydraulic fracturing units and associated methods
Embodiments of systems and methods disclosed provide a hydraulic fracturing unit that includes a reciprocating plunger pump configured to pump a fracturing fluid and a powertrain configured to power the reciprocating plunger pump. The powertrain includes a prime mover and a drivetrain, the prime mover including a gas turbine engine. The hydraulic fracturing unit also includes auxiliary equipment configured to support operation of the hydraulic fracturing unit including the reciprocating plunger pump and the powertrain. A power system is configured to power the auxiliary equipment. The power system includes a power source and a power network. The power source is configured to generate power for the auxiliary equipment. The power network is coupled to the power source and the auxiliary equipment, and configured to deliver the power generated by the power source to the auxiliary equipment. Associated systems including a plurality of hydraulic fracturing units are also provided.
1. A system for fracturing a well, the system comprising:
a plurality of hydraulic fracturing units, each of the plurality of hydraulic fracturing units comprising:
a chassis;
a reciprocating plunger pump connected to the chassis and configured to pump a fracturing fluid;
a powertrain connected to the chassis and configured to power the reciprocating plunger pump, the powertrain including a direct drive gas turbine engine and a drivetrain, the direct drive gas turbine engine operable using two or more different types of fuel; and
auxiliary equipment located onboard the chassis, the auxiliary equipment driven by electric motors to support operation of the hydraulic fracturing unit including the reciprocating plunger pump and the powertrain;
one or more electric power arrangements configured to power the auxiliary equipment of one or more of the plurality of hydraulic fracturing units, each electric power arrangement of the one or more electric power arrangements comprising an engine-generator set configured to generate electric power;
an electric power network configured to deliver electric power generated by at least one of the one or more electric power arrangements to the auxiliary equipment of the one or more of the plurality of hydraulic fracturing units, the electric power network being coupled to a first engine-generator set of a first hydraulic fracturing unit of the plurality of hydraulic fracturing units and first electric motors of the first hydraulic fracturing unit,
the electric power network being switchably connectable to one or more of a utility power grid, a battery bank, or an engine-generator set of a second hydraulic fracturing unit of the plurality of hydraulic fracturing units, and
the electric power network being configured to deliver electric power generated by the first engine-generator set to the first electric motors to drive first auxiliary equipment of the first hydraulic fracturing unit and to be switchably connected to the one or more of the utility power grid, the battery bank, or the second engine-generator set to deliver power to the first electric motors responsive to a failure or fault of the first engine-generator set; and
a manifold connected to respective reciprocating plunger pumps of the plurality of hydraulic fracturing units, the manifold configured to deliver fracturing fluid from the respective reciprocating plunger pumps to the well;
wherein the electric power network comprises an electric bus affixed to the manifold and connecting the one or more of the plurality of hydraulic fracturing units to the first electric power arrangement to power the one or more of the plurality of hydraulic fracturing units.
2. The system of claim 1 , wherein the first engine-generator set includes a diesel engine and an electric motor generator, the diesel engine configured to drive the electric motor generator to generate the electric power.
3. The system of claim 1 , wherein the first engine-generator set includes a gas turbine engine and an electric generator, the gas turbine engine configured to drive the electric generator to generate the electric power.
4. The system of claim 1 , wherein the first electric power arrangement further comprises a connection to the utility power grid, and the electric power network is configured to switchably connect the utility power grid to the one or more of the plurality of electric motors to deliver power to the first electric motors responsive to the failure or fault of the first engine-generator set.
5. The system of claim 1 , wherein the first electric power arrangement further comprises a battery bank chargeable from power generated by the first engine-generator set, and the electric power network is configured to switchably connect the battery bank to the one or more of the plurality of electric motors to deliver power to the first electric motors responsive to the failure or fault of the first engine-generator set.
6. The system of claim 1 , wherein the first electric power arrangement further comprises a connection to the engine-generator set of the second hydraulic fracturing unit, and the electric power network is configured to switchably connect the engine-generator set of the second hydraulic fracturing unit to the one or more of the plurality of electric motors to deliver power to the first electric motors responsive to the failure or fault of the first engine-generator set.
7. The system of claim 1 , wherein the one or more electric power arrangements include a plurality of electric power arrangements, each of the plurality of electric power arrangements being connected to a chassis of a respective one of the plurality of hydraulic fracturing units.
8. The system of claim 7 , wherein the first electric power arrangement is connected to the engine-generator set of the second hydraulic fracturing unit, and
wherein the electric power network is configured to switchably connect the engine-generator set of the second hydraulic fracturing unit to the one or more of the plurality of electric motors to deliver power to the first electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set of the first hydraulic fracturing unit.
9. The system of claim 7 , further comprising a battery bank connected to the plurality of electric power arrangements, engine-generator sets of the plurality of electric power arrangements being configured to generate electric power from which the battery bank is chargeable, and
wherein the electric power network is configured to switchably connect the battery bank to the one or more of the plurality of electric motors to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set of the first hydraulic fracturing unit.
10. The system of claim 9 , wherein the battery bank is configured to be connected to the utility power grid, and the first electric power arrangement is switchably connectable to the utility power grid via the battery bank.
11. The system of claim 9 , wherein the electric bus connects the plurality of electric power arrangements to the battery bank.
12. The system of claim 1 , further comprising a battery bank connected to the first electric power arrangement, wherein the electric power network is configured to switchably connect the battery bank to the one or more of the plurality of electric motors to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set of the first hydraulic fracturing unit.
13. The system of claim 12 , wherein the first electric power arrangement further comprises a connection to the utility power grid, and the electric power network is configured to switchably connect the utility power grid to the one or more of the plurality of electric motors to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set of the first hydraulic fracturing unit.
14. A method of fracturing a well, the method comprising:
arranging a plurality of hydraulic fracturing units, each hydraulic fracturing unit comprising:
a chassis;
a reciprocating plunger pump connected to the chassis and configured to pump a fracturing fluid;
a powertrain connected to the chassis and configured to power the reciprocating plunger pump, the powertrain including a direct drive gas turbine engine and a drivetrain, the direct drive gas turbine engine operable using two or more different types of fuel; and
auxiliary equipment located onboard the chassis, the auxiliary equipment driven by a plurality of electric motors to support operation of the hydraulic fracturing unit including the reciprocating plunger pump and the powertrain;
arranging one or more electric power arrangements to power the auxiliary equipment of one or more of the plurality of hydraulic fracturing units, each electric power arrangement comprising an engine-generator set configured to generate electric power;
arranging an electric power network to deliver electric power generated by at least one of the one or more electric power arrangements to the auxiliary equipment of the one or more of the plurality of hydraulic fracturing units, the electric power network comprising an electric bus coupled to a first engine-generator set of a first hydraulic fracturing unit of the plurality of hydraulic fracturing units and one or more of the plurality of electric motors of the first hydraulic fracturing unit,
the electric power network being switchably connectable to one or more of a utility power grid, a battery bank, or an engine-generator set of a second hydraulic fracturing unit of the one or more hydraulic fracturing units, and
the electric power network being configured to deliver electric power generated by the first engine-generator set to the one or more of the plurality of electric motors of the first hydraulic fracturing unit to drive first auxiliary equipment of the first hydraulic fracturing unit and to be switchably connected to the one or more of the utility power grid, the battery bank, or the engine-generator set of the second hydraulic fracturing unit to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to a failure or fault of the first engine-generator set;
connecting a manifold to respective reciprocating plunger pumps of the plurality of hydraulic fracturing units, the manifold being configured to deliver fracturing fluid from the respective reciprocating plunger pumps to the well;
affixing the electric bus of the electric power network to the manifold;
operating a first powertrain of the first hydraulic fracturing unit to power a first reciprocating plunger pump of the first hydraulic fracturing unit to pump the fracturing fluid, and
operating the first electric power arrangement to power the first auxiliary equipment.
15. The method of claim 14 , wherein the first engine-generator set includes a diesel engine and an electric motor generator, and operating the first electric power arrangement includes operating the diesel engine to drive the electric motor generator to generate electric power.
16. The method of claim 14 , wherein the first engine-generator set includes a gas turbine engine and an electric generator, and operating the first electric power arrangement includes operating the gas turbine engine to drive the electric generator to generate electric power.
17. The method of claim 14 , wherein the first electric power arrangement further comprises a connection to the utility power grid, and operating the first electric power arrangement includes connecting the electric power network to the utility power grid to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set.
18. The method of claim 14 , wherein the first electric power arrangement further comprises a battery bank configured to be charged by power generated by the first engine-generator set, and operating the first electric power arrangement includes connecting the first electric power arrangement to the battery bank to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to the failure or fault of first the engine-generator set.
19. The method of claim 14 , wherein the first electric power arrangement further comprises a connection to the engine-generator set of the second hydraulic fracturing unit, and operating the first electric power arrangement includes connecting the first electric power arrangement to the engine-generator set of the second hydraulic fracturing unit to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set.
20. The method of claim 14 , wherein the one or more electric power arrangements include a plurality of electric power arrangements, and arranging the plurality of electric power arrangements includes connecting each of the plurality of electric power arrangements to a respective chassis of each of the one or more of the plurality of hydraulic fracturing units.
21. The method of claim 14 , wherein arranging the one or more electric power arrangements includes connecting the one or more of the plurality of hydraulic fracturing units to the first electric power arrangement to supply power to the auxiliary equipment of the one or more of the plurality of hydraulic fracturing units.
22. The method of claim 21 , further comprising connecting the first electric power arrangement to the engine-generator set of the second hydraulic fracturing unit, and connecting the engine-generator set of the second hydraulic fracturing unit to the one or more of the plurality of electric motors of the first hydraulic fracturing unit to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set of the first hydraulic fracturing unit.
23. The method of claim 21 , wherein the one or more electric power arrangements include a plurality of electric power arrangements, the method further comprising:
connecting a battery bank to the plurality of electric power arrangements;
operating engine-generator sets of the plurality of electric power arrangements to charge the battery bank; and
supplying the one or more of the plurality of electric motors of the first hydraulic fracturing unit with power from the battery bank responsive to the failure or fault of the first engine-generator set of the first hydraulic fracturing unit.