Methods and systems for supplying fuel to gas turbine engines
Methods and systems for supply of fuel for a turbine-driven fracturing pump system used in hydraulic fracturing may be configured to identify when the supply pressure of primary fuel to a plurality of gas turbine engines of a plurality of hydraulic fracturing units falls below a set point, identify a gas turbine engine of the fleet of hydraulic fracturing units operating on primary fuel with highest amount of secondary fuel available, and to selectively transfer the gas turbine engine operating on primary fuel with the highest amount of secondary fuel from primary fuel operation to secondary fuel operation. Some methods and systems may be configured to transfer all gas turbine engines to secondary fuel operation and individually and/or sequentially restore operation to primary fuel operation and/or to manage primary fuel operation and/or secondary fuel operation for portions of the plurality of gas turbine engines.
1. A method of controlling fuel supply to a plurality of gas turbine engines associated with a hydraulic fracturing system, the method comprising:
(a) receiving a signal indicating that supply pressure of primary fuel to one or more gas turbine engines of the plurality of gas turbine engines falls below a set point;
(b) based at least in part on the signal:
initiating a timer; and
increasing a data sampling rate associated with the plurality of gas turbine engines;
(c) determining that the supply pressure of primary fuel to the one or more gas turbine engines remains below the set point when the timer reaches a predetermined end time;
(d) identifying a gas turbine engine of the plurality of gas turbine engines operating on primary fuel having a highest amount of secondary fuel available; and
(e) causing supply of secondary fuel to the identified gas turbine engine in place of at least some of the primary fuel supplied to the identified gas turbine engine.
2. The method of claim 1 , further comprising repeating steps (a), (b), (c), (d), and (e) for at least some gas turbine engines still operating using primary fuel.
3. The method of claim 1 , further comprising:
receiving a second signal indicating that supply pressure of primary fuel to the one or more gas turbine engines rises above a second set point;
based at least in part on the second signal, initiating a second timer;
determining that the supply pressure of primary fuel to the one or more gas turbine engines remains above the second set point when the second timer reaches a second predetermined end time; and
transferring the one or more gas turbine engines to primary fuel operation.
4. The method of claim 3 , further comprising decreasing the data sampling rate for the one or more gas turbine engines operating on primary fuel operation.
5. The method of claim 1 , wherein the identifying the gas turbine engine of the plurality of gas turbine engines operating on primary fuel with highest volume of secondary fuel comprises comparing level sensor measurements from the plurality of gas turbine engines.
6. The method of claim 1 , wherein the increasing the data sampling rate comprises increasing the data sampling rate by a factor of at least 2.
7. The method of claim 1 , further comprising:
receiving an indication of secondary fuel level below a minimum level for one or more gas turbine engines operating on secondary fuel; and
shutting down the one or more gas turbine engines operating on secondary fuel.
8. The method of claim 1 , further comprising:
receiving a measurement of differential pressure for one or more primary fuel filters associated with each gas turbine engine operating on primary fuel; and
when the differential pressure increases above a predetermined differential pressure, transferring the associated gas turbine engine from primary fuel operation to secondary fuel operation.
9. The method of claim 1 , further comprising:
receiving a measurement of differential pressure for one or more primary fuel filters associated with each gas turbine engine operating on primary fuel.
10. The method of claim 1 , wherein transferring the gas turbine engine from primary fuel operation to secondary fuel operation comprises gradually closing one or more valves associated with primary fuel operation while gradually opening one or more valves associated with secondary fuel operation.
11. A system for controlling fuel supply to a plurality of gas turbine engines associated with a hydraulic fracturing system, the system comprising:
a plurality of gas turbine engines associated with a plurality of pumps; and
a controller in communication with the plurality of gas turbine engines, the controller comprising a memory with computer-readable instructions operable to:
(a) receive a signal indicating when supply pressure of primary fuel to one or more gas turbine engines of the plurality of gas turbine engines falls below a set point;
(b) based at least in part on the signal:
initiate a timer; and
increase a data sampling rate associated with the plurality of gas turbine engines;
(c) determine that the supply pressure of primary fuel to the one or more gas turbine engines remains below the set point when the timer reaches a predetermined end time;
(d) identify a gas turbine engine of the plurality of gas turbine engines operating on primary fuel with a highest amount of secondary fuel available; and
(e) transfer the gas turbine engine operating on primary fuel with highest amount of secondary fuel available from primary fuel operation to secondary fuel operation.
12. The system of claim 11 , wherein the controller further is operable to repeat steps (a), (b), (c), and (e) for at least some of the other gas turbine engines of the plurality of gas turbine engines.
13. The system of claim 11 , wherein each of the plurality of gas turbine engines connects to a pump, and each of the gas turbine engines and connected pumps comprises a directly-driven turbine fracturing pump.
14. The system of claim 11 , wherein the primary fuel comprises a gaseous fuel, and the secondary fuel comprises diesel fuel.
15. The system of claim 11 , wherein the controller is further operable to:
receive a second signal indicating that a supply pressure of primary fuel to one or more gas turbine engines associated with the plurality of gas turbine engines rises above a second set point,
based at least in part on the second signal, initiate a second timer,
determine that the supply pressure of primary fuel to the one or more gas turbine engines remains above the second set point when the second timer reaches a second predetermined end time, and
transfer the one or more gas turbine engines to primary fuel operation.
16. The system of claim 15 , wherein the controller further is operable to decrease the data sampling rate for the one or more gas turbine engines operating on primary fuel operation.
17. The system of claim 11 , further comprising:
a plurality of secondary sensors configured to generate a secondary signal indicative of an amount of secondary fuel in a secondary fuel supply, and wherein the secondary sensors comprise one or more of a RADAR level sensor, a guided-wave RADAR level sensor, an ultrasonic level sensor, a capacitive level sensor, a hydrostatic level sensor, a probe-type level sensor, a float-type level sensor, a RF admittance level sensor, or an electro-optical level sensor.
18. The system of claim 11 , wherein increasing the data sampling rate comprises increasing the data sampling rate by a factor of at least 2.
19. The system of claim 11 , wherein the controller further is operable to:
receive a signal indicative of a secondary fuel level below a minimum level for one or more gas turbine engines operating on secondary fuel, and
shut down the one or more gas turbine engines operating on secondary fuel.
20. The system of claim 11 , wherein the controller further is operable:
to receive a measurement of differential pressure for a primary fuel filter associated with each gas turbine engine operating on primary fuel, and
when the differential pressure increases above a predetermined differential pressure for one of the gas turbine engines, transfer the one gas turbine engine from primary fuel operation to secondary fuel operation.
21. The system of claim 11 , wherein the controller comprises one or more of: a micro-controller, a supervisory control and data acquisition (SCADA) system, a computer, a programmable logic controller (PLC), a remote terminal unit (RTU), or a distributed control system (DCS).
22. The system of claim 11 , wherein the primary fuel is supplied to the one or more gas turbine engines via one or more: of a hybrid hub system, a multiple hub and spoke system, or a daisy chain system.