IP Library Granted Patent US 11,686,188
Granted Patent B1
US 11,686,188 · App. 18/049,320 · Granted Jun 27, 2023

Systems and methods for conditioning a gas

Inventor: Christopher A. Fournier (Fort Worth, TX)
Assignee: PROFRAC SERVICES, LLC
E21B43/35E21B34/02E21B43/2607E21B2200/04
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Quick Facts
Patent No.
US 11,686,188
App. No.
18/049,320
Granted
Jun 27, 2023
Kind
B1
Abstract

A system for conditioning a gas includes an inlet configured to receive the gas from a gas source. The system also includes a strainer downstream from the inlet. The strainer is configured to remove debris from the gas. The system also includes a first flowpath downstream from the strainer. The first flowpath includes a first pressure regulator that is configured to regulate a pressure of the gas by a first amount. The system also includes a second flowpath downstream from the strainer. The first and second flowpaths are parallel. The second flowpath includes a second pressure regulator that is configured to regulate the pressure of the gas by a second amount. The system also includes one or more flowpath valves downstream from the strainer and upstream from the first pressure regulator, the second pressure regulator, or both.

Claims (49)

1. A system for conditioning a gas, the system comprising:

an inlet configured to receive the gas from a gas source;

a first flowpath downstream from the inlet, wherein the first flowpath comprises a first pressure regulator that is configured to regulate a pressure of the gas by a first amount;

a second flowpath downstream from the inlet, wherein the first and second flowpaths are parallel, and wherein the second flowpath comprises a second pressure regulator that is configured to regulate the pressure of the gas by a second amount that is different than the first amount;

one or more flowpath valves downstream from the inlet and upstream from the first pressure regulator, the second pressure regulator, or both, wherein the one or more flowpath valves are configured to actuate between a first position and a second position, wherein the one or more flowpath valves are configured to direct the gas to flow through the first flowpath and prevent the gas from flowing through the second flowpath while in the first position, and wherein the one or more flowpath valves are configured to direct the gas to flow through the second flowpath and prevent the gas from flowing through the first flowpath while in the second position; and

an outlet downstream from the first and second flowpaths, wherein the outlet is configured to discharge the gas.

2. The system of claim 1 , wherein the gas source comprises a pipeline, a wellbore, or a vehicle, wherein the gas comprises raw natural gas, compressed natural gas, liquid natural gas, or a combination thereof, and wherein the inlet is configured to receive the natural gas at any pressure ranging from about 100 psi to about 1440 psi.

3. The system of claim 1 , wherein the first amount is between about 1 psi and about 100 psi, and wherein the second amount is between about 100 psi and about 1000 psi.

4. The system of claim 1 , wherein the gas source comprises a pipeline, and wherein the one or more flowpath valves are configured to actuate in response to the pressure of the gas from the pipeline falling below a predetermined pressure threshold.

5. The system of claim 4 , wherein the one or more flowpath valves are configured to actuate while the gas continues to flow through the system.

6. The system of claim 1 , wherein the second flowpath also comprises a third pressure regulator that is upstream from the second pressure regulator, wherein the third pressure regulator is configured to monitor the pressure of the gas downstream from the second pressure regulator and to regulate the pressure of the gas by a third amount in response to the monitored pressure being greater than a predetermined pressure threshold, wherein the third amount is different from the first amount and the second amount.

7. The system of claim 1 , further comprising an actuated ball valve positioned upstream from the first and second flowpaths, wherein the actuated ball valve is configured to automatically actuate into a closed position to prevent the gas from flowing therethrough in response to the pressure of the gas, downstream from the first pressure regulator, the second pressure regulator, or both, being greater than a predetermined pressure threshold.

8. The system of claim 7 , further comprising a British thermal unit (BTU) measurement pipeline tap positioned downstream from the first and second flowpaths, wherein the BTU measurement pipeline tap is configured to measure the BTUs of the gas, and wherein the actuated ball valve is configured to actuate into the closed position in response to the measured BTUs being greater than or less than a predetermined BTU threshold.

9. The system of claim 1 , wherein the one or more flowpath valves are configured to actuate between the first position, the second position, and a third position, and wherein the one or more flowpath valves are configured to direct a first portion of the gas to flow through the first flowpath and a second portion of the gas to simultaneously flow through the second flowpath while in the third position.

10. The system of claim 1 , wherein the system does not comprise an overprotection relief valve that is configured to vent the gas to the atmosphere.

11. A system for conditioning a natural gas, the system comprising:

an inlet configured to receive the natural gas from a gas source;

a strainer downstream from the inlet, wherein the strainer is configured to remove debris from the natural gas;

a first flowpath downstream from the strainer, wherein the first flowpath comprises a first pressure regulator that is configured to regulate a pressure of the natural gas by a first amount that is between about 1 psi and about 100 psi;

a second flowpath downstream from the strainer, wherein the first and second flowpaths are parallel, wherein the second flowpath comprises a second pressure regulator and a third pressure regulator, and wherein the second pressure regulator is configured to regulate the pressure of the natural gas by a second amount that is between about 100 psi and about 1000 psi;

one or more flowpath valves downstream from the strainer and upstream from the first pressure regulator, the second pressure regulator, the third pressure regulator, or a combination thereof, wherein the one or more flowpath valves are configured to actuate between a first position and a second position, wherein the one or more flowpath valves are configured to direct the natural gas to flow through the first flowpath and prevent the natural gas from flowing through the second flowpath while in the first position, and wherein the one or more flowpath valves are configured to direct the natural gas to flow through the second flowpath and prevent the natural gas from flowing through the first flowpath while in the second position; and

an outlet downstream from the first and second flowpaths, wherein the outlet is configured to discharge the natural gas.

12. The system of claim 11 , wherein the third pressure regulator is upstream from the second pressure regulator, wherein the third pressure regulator comprises a monitor pressure regulator that is configured to monitor the pressure of the natural gas downstream from the second pressure regulator and to regulate the pressure of the natural gas in response to the monitored pressure being greater than a predetermined pressure threshold.

13. The system of claim 12 , further comprising a ball valve positioned between the inlet and the one or more flowpath valves, wherein the ball valve is configured to automatically actuate into a closed position to prevent the natural gas from flowing therethrough in response to the pressure of the natural gas, downstream from the first and second flowpaths being greater than the predetermined pressure threshold.

14. The system of claim 11 , further comprising:

a ball valve positioned between the inlet and the one or more flowpath valves; and

a British thermal unit (BTU) measurement pipeline tap positioned downstream from the first and second flowpaths, wherein the BTU measurement pipeline tap is configured to measure the BTUs of the natural gas,

wherein the ball valve is configured to automatically actuate into a closed state to prevent the natural gas from flowing therethrough in response to the measured BTUs being greater than or less than a BTU threshold.

15. The system of claim 11 , further comprising:

a ball valve positioned between the inlet and the one or more flowpath valves; and

a gas scrubber positioned downstream from the first and second flowpaths, wherein the gas scrubber is configured to remove liquid from the natural gas,

wherein the ball valve is configured to automatically actuate into a closed state to prevent the natural gas from flowing therethrough in response to a liquid level in the scrubber being greater than a liquid threshold.

16. A method for conditioning a gas, the method comprising:

connecting an inlet of a system to a gas source;

connecting an outlet of the system to equipment;

actuating one or more flowpath valves of the system into a first position to direct gas from the gas source to flow through a first flowpath of the system and not a second flowpath of the system, wherein the first and second flowpaths are parallel, wherein the first flowpath comprises a first pressure regulator that is configured to regulate a pressure of the gas by a first amount, and wherein the second flowpath comprises a second pressure regulator that is configured to regulate the pressure of the gas by a second amount that is different than the first amount; and

conditioning the gas with the system, wherein conditioning the gas comprises:

receiving the gas from the gas source;

removing debris from the gas;

regulating the pressure of the gas; and

discharging the gas to the equipment which uses the gas as a fuel.

17. The method of claim 16 , further comprising actuating the one or more flowpath valves of the system into a second position to direct the gas from the gas source to flow through the second flowpath and not the first flowpath in response to the pressure of the gas at the source changing.

18. The method of claim 16 , further comprising modifying, repairing, or replacing the second pressure regulator while the one or more flowpath valves are in the first position and the gas is flowing through the first flowpath.

19. The method of claim 16 , further comprising:

measuring British thermal units (BTUs) of the gas downstream from the first and second flowpaths; and

tuning the equipment based at least partially upon the measured BTUs, wherein the equipment comprises a hydraulic fracturing engine.

20. The method of claim 16 , further comprising:

measuring British thermal units (BTUs) of the gas downstream from the first and second flowpaths; and

actuating a ball valve into a closed position in response to the measured BTUs being greater than or less than a predetermined BTU threshold, wherein the ball valve is positioned downstream from the inlet and upstream from the one or more flowpath valves.

Assignments (7)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 1, 2025
From: PROFRAC SERVICES, LLC
To: PWRTEK, LLC
Reel/Frame 071000/0321 →
SECURITY INTEREST Recorded Apr 29, 2025
From: PWRTEK, LLC
To: PROFRAC GDM, LLC
Reel/Frame 070974/0062 →
RELEASE OF SECURITY INTEREST Recorded Apr 28, 2025
From: JPMORGAN CHASE BANK, N.A.
To: PROFRAC SERVICES, LLC
Reel/Frame 070957/0054 →
PARTIAL RELEASE OF SECURITY INTEREST IN INTELLECTUAL PROPERTY COLLATERAL (INDENTURE) Recorded Apr 28, 2025
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
To: PROFRAC SERVICES, LLC
Reel/Frame 071095/0581 →
SECURITY INTEREST Recorded Jan 11, 2024
From: PROFRAC SERVICES, LLC; U.S. WELL SERVICES, LLC; BEST PUMP AND FLOW, LLC
To: JPMORGAN CHASE BANK, N.A.
Reel/Frame 066104/0536 →
INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Jan 3, 2024
From: FTS INTERNATIONAL SERVICES, LLC; U.S. WELL SERVICES, LLC; PROFRAC SERVICES, LLC; U.S. WELL SERVICES HOLDINGS, LLC; BEST PUMP AND FLOW, LLC
To: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION, AS COLLATERAL AGENT
Reel/Frame 066186/0752 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 25, 2022
From: FOURNIER, CHRISTOPHER A.
To: PROFRAC SERVICES, LLC
Reel/Frame 061524/0807 →
Continuity (1)
Division 17873688 · Jul 26, 2022
Cited By (3)
US 12,378,922 US 12,521,669 US 12,589,351