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 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, and
auxiliary equipment located onboard the chassis, the auxiliary equipment driven by an electric motor to support operation of the hydraulic fracturing unit including the reciprocating plunger pump and the powertrain;
an electric power arrangement configured to power the auxiliary equipment, the electric power arrangement comprising an engine-generator set configured to generate electric power;
an electric power network configured to deliver electric power generated by the engine-generator set to the electric motor, the electric power network being connected to the engine-generator set and the electric motor, the electric power network switchably being connectable to a utility power grid, a battery bank, or another engine-generator set and being configured to deliver electric power generated by the engine-generator set of the electric power arrangement to the electric motor to drive the auxiliary equipment and switchably to be connected to the utility power grid, the battery bank, or the another engine-generator set responsive to a failure or fault of the engine-generator set of the electric power arrangement; and
a manifold connected to the reciprocating plunger pump, the manifold configured to deliver fracturing fluid from the reciprocating plunger pump to the well, the electric power network further comprises an electric bus affixed to the manifold and positioned to connect the hydraulic fracturing unit to the electric power arrangement.
2. The system of claim 1 , wherein the engine-generator set of the electric power arrangement 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 engine-generator set of the electric power arrangement 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 electric power arrangement further comprises a connection to the utility power grid, and the electric power network further is configured to connect the utility power grid to the electric motor to deliver power to the electric motor responsive to the failure or fault of the engine-generator set of the electric power arrangement.
5. The system of claim 1 , further comprising a battery bank chargeable by the engine-generator set of the electric power arrangement, and the electric power network further is configured to connect the battery bank to the electric motor responsive to the failure or fault of the engine-generator set of the electric power arrangement.
6. The system of claim 1 , wherein the electric power arrangement further comprises a connection to the another engine-generator set, and the electric power network further is configured to connect the another engine-generator set to the electric motor responsive to the failure or fault of the engine-generator set of the electric power arrangement.
7. The system of claim 1 , further comprising a plurality of hydraulic fracturing units and a plurality of electric power arrangements, wherein the hydraulic fracturing unit comprises one of the plurality of hydraulic fracturing units, and wherein the electric power arrangement comprises one of the 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 each of the plurality of electric power arrangements is connected to the engine-generator set of an associated one of the plurality of electric power arrangements, and
wherein the electric power network further is configured to connect the engine-generator set of a first of the plurality of electric power arrangements to the electric motor of a first of the plurality of hydraulic fracturing units responsive to the failure or fault of a second of the plurality of electric power arrangements.
9. The system of claim 7 , wherein the battery bank is connected to the plurality of electric power arrangements, wherein each engine-generator set of the plurality of electric power arrangements is configured to generate electric power from which the battery bank is chargeable, and wherein the electric power network further is configured to connect the battery bank to the electric motors of the plurality of hydraulic fracturing units responsive to a failure or fault of the engine-generator set of a first of the plurality of electric power arrangements.
10. The system of claim 9 , wherein the battery bank is configured to be connected to the utility power grid, and wherein the electric power network further is configured to connect the electric power network 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 , wherein the battery bank is connected to the electric power arrangement, and wherein the electric power network further is configured to connect the battery bank to the electric motor responsive to the failure or fault of the engine-generator set of the electric power arrangement.
13. The system of claim 12 , wherein the electric power arrangement further comprises a connection to the utility power grid, and the electric power network further is configured to connect the utility power grid to the electric motor responsive to the failure or fault of the engine-generator set of the electric power arrangement.
14. The system of claim 1 , wherein the powertrain includes a direct drive gas turbine engine and a drivetrain.
15. A method of fracturing a well, the method comprising:
(A) providing a hydraulic fracturing unit, the 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, and
auxiliary equipment located onboard the chassis, the auxiliary equipment driven by an electric motor to support operation of the hydraulic fracturing unit;
(B) arranging an electric power arrangement to power the auxiliary equipment, the electric power arrangement comprising an engine-generator set configured to generate electric power;
(C) arranging an electric power network to deliver electric power generated by the electric power arrangement to the electric motor, the electric power network comprising an electric bus connected to the engine-generator set and the electric motor, the electric power network also configured to connect to one or more of a utility power grid, a battery bank, or another engine-generator set, and the electric power network also configured to deliver electric power generated by the engine-generator set of the electric power arrangement to the electric motor and to the one or more of (1) the utility power grid, (2) the battery bank, or (3) the another engine-generator set, when connected thereto, responsive to a failure or fault of the engine-generator set of the electric power arrangement;
(D) connecting a manifold to the reciprocating plunger pump, the manifold being configured to deliver fracturing fluid from the reciprocating plunger pump to the well;
(E) operating the powertrain to power the reciprocating plunger pump to pump the fracturing fluid; and
(F) operating the electric power arrangement to power the auxiliary equipment.
16. The method of claim 15 , wherein the engine-generator set of the electric power arrangement includes a diesel engine and an electric motor generator, and wherein the step of operating the electric power arrangement includes operating the diesel engine to drive the electric motor generator.
17. The method of claim 15 , wherein the engine-generator set of the electric power arrangement includes a gas turbine engine and an electric generator, and wherein the step of operating the electric power arrangement includes operating the gas turbine engine to drive the electric generator.
18. The method of claim 15 , wherein the electric power arrangement further comprises a connection to the utility power grid, and wherein the step of operating the electric power arrangement includes connecting the electric power network to the utility power grid to deliver power to the electric motor responsive to the failure or fault of the engine-generator set of the electric power arrangement.
19. The method of claim 15 , further comprising providing the battery bank such that the battery bank is configured to be charged by the engine-generator set of the electric power arrangement, and wherein the step of operating the electric power arrangement includes connecting the electric power arrangement to the battery bank to deliver electric power to the electric motors responsive to the failure or fault of the engine-generator set of the electric power arrangement.
20. The method of claim 15 , wherein the electric power arrangement further comprises a connection to the another engine-generator set, and wherein the step of operating the electric power arrangement includes connecting the electric power arrangement to the another engine-generator set to deliver power to electric motor responsive to the failure or fault of the engine-generator set of the electric power arrangement.
21. The method of claim 15 , wherein the providing the hydraulic fracturing unit further comprises providing a plurality of hydraulic fracturing units and a plurality of electric power arrangements, wherein the hydraulic fracturing unit comprises one of the plurality of hydraulic fracturing units, wherein the electric power arrangement comprises one of a plurality of electric power arrangements, and wherein the step of arranging an electric power arrangement includes connecting the electric power arrangement to a chassis of the hydraulic fracturing unit.
22. The method of claim 15 , wherein the step of arranging the electric power arrangement includes connecting the hydraulic fracturing unit to the electric power arrangement to supply electric power to the auxiliary equipment of the hydraulic fracturing unit.
23. The method of claim 22 , further comprising connecting the electric power arrangement to the another engine-generator set, and connecting the another engine-generator set to the electric motor responsive to the failure or fault of the engine-generator set of the electric power arrangement.
24. The method of claim 23 , further comprising providing a plurality of electric power arrangements, wherein the electric power arrangement is one of the plurality of electric power arrangements, and the method further comprising:
connecting the 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 electric motor with electric power from the battery bank responsive to the failure or fault of the engine-generator set of at least one of the plurality of electric power arrangements.
25. The method of claim 15 , wherein the powertrain includes a direct drive gas turbine engine and a drivetrain.