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, the powertrain including a turbine engine and a drivetrain; and
auxiliary equipment located onboard the chassis, the auxiliary equipment driven by one or more 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, the one or more electric power arrangements comprising:
an engine-generator set configured to generate electric power, and
an electric power network configured to deliver electric power generated by the engine-generator set to the auxiliary equipment, the electric power network providing electrical communication between the engine-generator set and the one or more electric motors of the hydraulic fracturing unit, wherein the one or more electric power arrangements include a battery bank chargeable from the electric power generated by the engine-generator set, wherein the one or more electric power arrangements is configured to selectively (i) operate the battery bank as a buffer or (ii) bypass the battery bank, allowing the battery bank to act as a hub to supply power to the hydraulic fracturing unit; and
a manifold connected to the reciprocating plunger pump of the hydraulic fracturing unit, the manifold configured to deliver fracturing fluid from the reciprocating plunger pump to the well.
2 . The system of claim 1 , wherein the 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 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 electric power network is switchably connectable to one or more of a utility power grid, the battery bank, or another engine-generator set and is configured to deliver electric power generated by the engine-generator set to the one or more electric motors to drive auxiliary equipment of the hydraulic fracturing unit and to be switchably connected to the one or more of the utility power grid, the battery bank, or the another engine-generator set to deliver power to the one or more electric motors responsive to a failure or fault of the engine-generator set.
5 . The system of claim 4 , wherein the one or more electric power arrangements 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 electric motors to deliver power to the electric motors responsive to the failure or fault of the engine-generator set.
6 . The system of claim 4 , wherein the electric power network is configured to switchably connect the battery bank to the one or more electric motors to deliver power to the one or more electric motors responsive to the failure or fault of the engine-generator set.
7 . The system of claim 4 , wherein the electric power network further comprises a connection to a second hydraulic fracturing unit and is configured to deliver electric power generated by the engine-generator set to auxiliary equipment located onboard a chassis of the second hydraulic fracturing unit.
8 . 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 a plurality of hydraulic fracturing units.
9 . The system of claim 4 , wherein the one or more electric power arrangements further comprises a second engine-generator set, and
wherein the electric power network is configured to switchably connect the second engine-generator set to the one or more electric motors to deliver power to the electric motors responsive to the failure or fault of the engine-generator set.
10 . 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, the powertrain including an engine and a drivetrain comprising a reduction transmission; and
auxiliary equipment located onboard the chassis, the auxiliary equipment comprising a lube oil pump coupled to the reduction transmission, the auxiliary equipment driven by one or more 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, the one or more electric power arrangements comprising:
an engine-generator set configured to generate electric power, and
an electric power network configured to deliver electric power generated by the engine-generator set to the auxiliary equipment, the electric power network providing electrical communication between the engine-generator set and the one or more electric motors of the hydraulic fracturing unit, wherein the one or more electric power arrangements include a battery bank chargeable from the electric power generated by the engine-generator set, wherein the one or more electric power arrangements is configured to selectively (i) operate the battery bank as a buffer or (ii) bypass the battery bank, allowing the battery bank to act as a hub to supply power to the hydraulic fracturing unit; and
a manifold connected to the reciprocating plunger pump of the hydraulic fracturing unit, the manifold configured to deliver fracturing fluid from the reciprocating plunger pump to the well.
11 . The system of claim 10 , wherein the electric power network is switchably connectable to one or more of a utility power grid, the battery bank, or another engine-generator set and is configured to deliver electric power generated by the engine-generator set to the one or more electric motors to drive auxiliary equipment of the hydraulic fracturing unit and to be switchably connected to the one or more of the utility power grid, the battery bank, or the another engine-generator set to deliver power to the one or more electric motors responsive to a failure or fault of the engine-generator set.
12 . The system of claim 11 , wherein the one or more electric power arrangements 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 electric motors to deliver power to the electric motors responsive to the failure or fault of the engine-generator set.
13 . The system of claim 11 , wherein the electric power network is configured to switchably connect the battery bank to the one or more electric motors to deliver power to the one or more electric motors responsive to the failure or fault of the engine-generator set.
14 . The system of claim 11 , wherein the electric power network further comprises a connection to a second hydraulic fracturing unit and is configured to deliver electric power generated by the engine-generator set to auxiliary equipment located onboard a chassis of the second hydraulic fracturing unit.
15 . The system of claim 11 , wherein the one or more electric power arrangements further comprises a second engine-generator set, and
wherein the electric power network is configured to switchably connect the second engine-generator set to the one or more electric motors to deliver power to the electric motors responsive to the failure or fault of the engine-generator set.
16 . The system of claim 10 , 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 a plurality of hydraulic fracturing units.
17 . 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, the powertrain including an engine and a drivetrain comprising a reduction transmission;
one or more power takeoffs (PTOs) connected to the drivetrain; and
auxiliary equipment located onboard the chassis, the auxiliary equipment comprising a lube oil pump coupled to the reduction transmission, the auxiliary equipment driven by one or more electric motors 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, and
an electric power network configured to deliver electric power generated by the engine-generator set to the auxiliary equipment, the electric power network providing electrical communication between the engine-generator set and the one or more electric motors of the hydraulic fracturing unit, wherein the electric power arrangement includes a battery bank chargeable from the electric power generated by the engine-generator set, wherein the electric power arrangement is configured to selectively (i) operate the battery bank as a buffer or (ii) bypass the battery bank to act as a hub, allowing the battery bank to supply power to the hydraulic fracturing unit; and
a manifold connected to the reciprocating plunger pump of the hydraulic fracturing unit, the manifold configured to deliver fracturing fluid from the reciprocating plunger pump to the well.
18 . The system of claim 17 , wherein at least one of the one or more PTOs is connected to an alternator configured to generate electric power from which the auxiliary equipment may be powered.
19 . The system of claim 17 , wherein the electric power network is switchably connectable to one or more of a utility power grid, the battery bank, or another engine-generator set and is configured to deliver electric power generated by the engine-generator set to the one or more electric motors to drive auxiliary equipment of the hydraulic fracturing unit and to be switchably connected to the one or more of the utility power grid, the battery bank, or the another engine-generator set to deliver power to the one or more electric motors, and
wherein electric power generated by the alternator and not utilized by the auxiliary equipment is transferred to the utility power grid or the battery bank.