Granted Patent B2

US 12,326,075 · App. 18/596,860 · Granted Jun 10, 2025

Inventors: Tony Yeung (The Woodlands, TX); Ricardo Rodriguez-Ramon (The Woodlands, TX); Joseph Foster (The Woodlands, TX)

Assignee: BJ Energy Solutions, LLC

E21B43/2607E21B43/26E21B43/267E21B2200/22

Abstract

Claims (85)

1. A wellsite hydraulic fracturing pumper system, the system comprising:

one or more hydraulic fracturing pumps configured to provide a slurry to a wellhead in hydraulic fracturing pumping stages and when positioned at a hydrocarbon well site, each of the hydraulic fracturing pumps comprising a gas turbine engine mechanically linked to a hydraulic fracturing pump via a drive shaft; and

a controller to control the hydraulic fracturing pumps, the controller positioned in signal communication with a terminal, a computing device, and sensors included on the hydraulic fracturing pumps, the controller including a processor and a memory storing instructions, the instructions, when executed by the processor, to:

determine if the one or more hydraulic fracturing pumps are operable between 75 percent to 90 percent of a pressure rating;

in response to a determination that the one or more hydraulic fracturing pumps are operable between 75 percent and 90 percent of the pressure rating, communicate a prompt to the terminal to accept the one or more hydraulic fracturing pumps for use in a hydraulic fracturing pump stage; and

in response to an acceptance of use of the one or more hydraulic fracturing pumps operable between 75 percent and 90 percent of the pressure rating, communicate a prompt requesting a user to enter identification to confirm selection of the one or more hydraulic fracturing pumps.

2. The wellsite hydraulic fracturing pumper system of claim 1 , wherein the controller further includes instructions stored on the memory, when executed by the processor, to:

in response to a denial of use of the one or more hydraulic fracturing pumps operable between 75 percent and 90 percent of the pressure rating, discount the one or more hydraulic fracturing pumps; and

in response to a determination that the one or more hydraulic fracturing pumps are not operable between 75 percent and 90 percent of the pressure rating, discount the one or more hydraulic fracturing pumps.

3. The wellsite hydraulic fracturing pumper system of claim 1 , wherein the controller further includes instructions stored on the memory, when executed by the processor, to:

determine if hydraulic fracturing stage profiles are available for use in the hydraulic fracturing pumping stages;

in response to determination that the hydraulic fracturing stage profiles are not available for use, communicate a prompt at the terminal to enter hydraulic fracturing stage parameters for a current hydraulic fracturing stage profile and for a current hydraulic fracturing stage; and

in response to a determination that the hydraulic fracturing stage profiles are available for use, communicate a prompt at the terminal to utilize one of the hydraulic fracturing stage profiles or to amend one of the hydraulic fracturing stage profiles for the current hydraulic fracturing stage profile.

4. The wellsite hydraulic fracturing pumper system of claim 3 , wherein the controller further includes instructions stored on the memory, when executed by the processor, to:

in response to an entry or amendment of the hydraulic fracturing stage parameters for the current hydraulic fracturing stage profile at the terminal, store the current hydraulic fracturing stage profile to the computing device with an indicator to indicate that the current hydraulic fracturing stage profile is associated with the current hydraulic fracturing pumping stage, and

communicate a prompt to the terminal requesting acceptance of the use of the current hydraulic fracturing stage profile for the current hydraulic fracturing stage.

5. The wellsite hydraulic fracturing pumper system of claim 4 , further comprising:

a blender configured to provide the slurry, the slurry including fluid, chemicals, and proppant, to the hydraulic fracturing pumps;

a hydration unit to provide fluid to the blender;

a chemical additive unit to provide chemicals to the blender; and

a conveyor to provide proppant to the blender;

wherein the controller is configured to control one or more of the blender, the hydration unit, the chemical additive unit, and the conveyor.

6. The wellsite hydraulic fracturing pumper system of claim 5 , wherein the hydraulic fracturing stage parameters include:

an amount of fluid for the hydration unit to provide to the blender;

an amount and type of chemicals for the chemical additive unit to provide to the blender;

an amount and type of proppant for the conveyor to provide to the blender;

a flow rate of the slurry for the blender to indicate a rate of flow of the slurry to a set of hydraulic fracturing pumps;

a flow rate for the set of hydraulic fracturing pumps to indicate a rate of flow to the wellhead; and

the pressure rating and maximum pressure for the set of hydraulic fracturing pumps; and

wherein the controller further includes instructions stored on the memory, when executed by the processor, to:

in response to a reception of the acceptance of the use of the current hydraulic fracturing stage profile for the current hydraulic fracturing stage:

communicate the amount of fluid to be provided to the blender to a controller of the hydration unit;

communicate the amount and type of chemicals to the chemical additive unit;

communicate the amount and type of proppant to a controller of the conveyor; and

communicate the flow rate of the slurry to a blender flow meter of the blender.

7. The wellsite hydraulic fracturing pumper system of claim 6 , wherein the controller further includes instructions stored on the memory, when executed by the processor, to:

in response to a confirmation from the controller of the hydration unit, the controller of the chemical additive unit, the controller of the conveyor, and the blender flow meter that the hydraulic fracturing pumping stage parameters are received by the blender, hydration unit, chemical additive unit, and conveyor:

determine the set of hydraulic fracturing pumps to be utilized based on the flow rate, pressure rate, and maximum pressure in the current hydraulic fracturing stage profile and on available hydraulic fracturing pumps in the wellsite hydraulic fracturing pumper system; and

determine whether the set of hydraulic fracturing pumps meet the pressure rating and flow rate for the set of hydraulic fracturing pumps of the current hydraulic fracturing stage profile.

8. The wellsite hydraulic fracturing pumper system of claim 6 , wherein the controller further includes instructions stored on the memory, when executed by the processor, to:

in response to a determination that the set of hydraulic fracturing pumps meet the pressure rating and flow rate of the current hydraulic fracturing stage profile:

determine a power utilization of the set of hydraulic fracturing pumps;

in response to a determination that one or more hydraulic fracturing pumps are utilized at 75 percent maximum HP at 80 percent of maximum stage pressure and at full flow rate, communicate a notification to the terminal of poor power utilization and a prompt to accept increased power utilization of the set of hydraulic fracturing pumps; and

in response to an acceptance of the increased power utilization, move one of the one or more hydraulic fracturing pumps with poor power utilization offline at a time until the set of hydraulic fracturing pumps is not a poor power utilization state.

9. The wellsite hydraulic fracturing pumper system of claim 6 , wherein the controller further includes instructions stored on the memory, when executed by the processor, to:

in response to a determination that the set of hydraulic fracturing pumps are not exhibiting poor power utilization:

communicate a notification and request for confirmation of the set of hydraulic fracturing pumps to be utilized; and

in response to a reception of the confirmation of the set of hydraulic fracturing pumps to be utilized, start the current hydraulic fracturing stage.

10. The wellsite hydraulic fracturing pumper system of claim 6 , wherein the controller further includes instructions stored on the memory, when executed by the processor, to:

in response to a start of the current hydraulic fracturing stage, determine if further hydraulic fracturing stages are to occur; and

in response to a determination that further hydraulic fracturing stages are to occur, communicate a prompt to the terminal to utilize or amend one of the hydraulic fracturing stage profiles or the current hydraulic fracturing stage profile for a next hydraulic fracturing stage, wherein the prompt is communicated during execution of the current hydraulic fracturing stage.

11. The wellsite hydraulic fracturing pumper system of claim 6 , wherein the amended current hydraulic fracturing profile includes a time delay, the time delay to indicate when the current hydraulic fracturing stage begins.

12. The wellsite hydraulic fracturing pumper system of claim 6 , wherein availability for use of the hydraulic fracturing stage profiles is based on maintenance data associated with the hydraulic fracturing pumps.

13. The wellsite hydraulic fracturing pumper system of claim 6 , wherein availability for use of the hydraulic fracturing stage profiles is based on events associated with the hydraulic fracturing pumps.

14. The wellsite hydraulic fracturing pumper system of claim 5 , wherein one or more of a maximum rod load, a plunger diameter, a stroke length, a number of cylinders, and a maximum rpm for each hydraulic fracturing pump is stored on the memory of the controller.

15. The wellsite hydraulic fracturing pumper system of claim 5 , wherein the blender, the hydration unit, the chemical additive unit, and the conveyor are powered by one or more electrical generators located at the hydrocarbon well site, wherein each of the one or more electrical generators are driven by an internal combustion engine.

16. The wellsite hydraulic fracturing pumper system of claim 15 , wherein the internal combustion engine and the gas turbine engine mechanically linked to a hydraulic fracturing pump are connected to a source of fuel, wherein the source of fuel comprises one or more of CNG, line gas, or well-gas produced natural gas.

17. A hydraulic fracturing pumper system, the system comprising:

a plurality of hydraulic fracturing pumps configured to provide a slurry to a wellhead in hydraulic fracturing pumping stages and when positioned at a hydrocarbon well site, each of the plurality of hydraulic fracturing pumps comprising a gas turbine engine mechanically linked to a hydraulic fracturing pump via a drive shaft;

a controller for the hydraulic fracturing pumper system, the controller comprising:

a terminal input/output in signal communication with a terminal such that the controller is configured to:

provide a prompt to the terminal to enter data for a hydraulic fracturing stage of a plurality of hydraulic fracturing stages into a first hydraulic fracturing stage profile;

receive the first hydraulic fracturing stage profile from the terminal input/output;

in response to a determination that hydraulic fracturing stage profiles are available for use, provide a prompt to the terminal requesting utilization or amendment of one of the hydraulic fracturing stage profiles for another hydraulic fracturing stage of the plurality of hydraulic fracturing stages;

receive acceptance of the use of one of the hydraulic fracturing stage profiles for the another hydraulic fracturing stage;

receive an amended hydraulic fracturing stage profile of the hydraulic fracturing stage profiles for the another hydraulic fracturing stage;

a server input/output in signal communication with a server such that each hydraulic fracturing stage profile, including indicators of associated hydraulic fracturing stages, are communicated between the controller and the server; and

a first control output in signal communication with hydraulic fracturing pumps such that the controller provides pump control signals based on a stage of the plurality of hydraulic fracturing stages and an associated hydraulic fracturing stage profile.

18. The hydraulic fracturing pumper system of claim 17 , further comprising:

a second output in signal communication with a blender to provide blender control signals based on the stage of the plurality of hydraulic fracturing stages and the associated hydraulic fracturing stage profile;

a third output in signal communication with a chemical additive unit to provide chemical additive unit control signals based on the stage of the plurality of hydraulic fracturing stages and the associated hydraulic fracturing stage profile; and

a fourth output in signal communication with a hydration unit to provide hydration unit control signals based on the stage of the plurality of hydraulic fracturing stages and the associated hydraulic fracturing stage profile.

19. A hydraulic fracturing pumper system, the system comprising:

a plurality of hydraulic fracturing pumps configured to provide a slurry to a wellhead in hydraulic fracturing pumping stages and when positioned at a hydrocarbon well site, each of the plurality of hydraulic fracturing pumps comprising a gas turbine engine mechanically linked to a hydraulic fracturing pump via a drive shaft;

wherein each of the plurality of hydraulic fracturing pumps configured to be in signal communication with a controller for the hydraulic fracturing pumper system, the controller comprising:

a terminal input/output in signal communication with a terminal such that the controller is configured to:

provide a prompt to the terminal to enter data for a hydraulic fracturing stage of a plurality of hydraulic fracturing stages into a first hydraulic fracturing stage profile;

receive the first hydraulic fracturing stage profile from the terminal input/output;

in response to a determination that hydraulic fracturing stage profiles are available for use, provide a prompt to the terminal requesting utilization or amendment of one of the hydraulic fracturing stage profiles for another hydraulic fracturing stage of the plurality of hydraulic fracturing stages;

receive acceptance of the use of one of the hydraulic fracturing stage profiles for the another hydraulic fracturing stage;

receive an amended hydraulic fracturing stage profile of the hydraulic fracturing stage profiles for the another hydraulic fracturing stage;

a server input/output in signal communication with a server such that each hydraulic fracturing stage profile, including indicators of associated hydraulic fracturing stages, are communicated between the controller and the server; and

a first control output in signal communication with hydraulic fracturing pumps such that the controller provides pump control signals based on a stage of the plurality of hydraulic fracturing stages and an associated hydraulic fracturing stage profile.

20. The hydraulic fracturing pumper system of claim 19 , further comprising:

a blender, a hydration unit, a chemical additive unit, and a conveyor, each powered by one or more electrical generators located at the hydrocarbon well site, wherein each of the one or more electrical generators are driven by an internal combustion engine, wherein the internal combustion engine and the gas turbine engine mechanically linked to a hydraulic fracturing pump are connected to a source of fuel, wherein the source of fuel comprises one or more of CNG, line gas, or well-gas produced natural gas.

Assignments (3)

Continuity (8)

References Cited (400)