Hybrid drive and distributed power systems for well stimulation operations
A hybrid drive system that uses multiple sources of mechanical energy to drive an oilfield apparatus is provided. The hybrid drive system may include a first mover for generating first mechanical energy, the oilfield apparatus, a drivetrain for providing first mechanical energy from the first mover to the oilfield apparatus, and a second mover to generate and provide second mechanical energy to the oilfield apparatus. The second mover comprises an electric motor/generator. The second mover can, at times, be operable to provide excess power that can be used elsewhere at the wellsite.
1 . An apparatus, comprising:
one or a plurality of hybrid units, each hybrid unit comprising:
a first mover for generating a first mechanical energy, wherein the first mover comprises an internal combustion engine;
a hybrid unit oilfield apparatus;
a drivetrain for providing the first mechanical energy from the first mover to the hybrid unit oilfield apparatus; and
a second mover, wherein the second mover comprises an electric motor/generator, that generates and provides a second mechanical energy to the hybrid unit oilfield apparatus and, generates electrical power,
wherein the drivetrain outputs the first mechanical energy and the second mechanical energy directly to the hybrid unit oilfield apparatus, the combined first and second mechanical energies providing a torque sufficient to drive the hybrid unit oilfield apparatus, and
wherein the hybrid unit oilfield apparatus of a first of the one or the plurality of hybrid units comprises a well stimulation pump comprising a reciprocating pump, and wherein an auxiliary apparatus is at least in part powered at times by excess electrical power generated by the second mover, wherein the auxiliary apparatus is selected from a blender, a wellbore services manifold trailer, a conveyor, a datavan or a combination thereof.
2 . The apparatus of claim 1 comprising the plurality of hybrid units, wherein the hybrid unit oilfield apparatus of a second of the plurality of hybrid units comprises auxiliary apparatus selected from a blender, a wellbore services manifold trailer, a conveyor, a datavan or a combination thereof.
3 . The apparatus of claim 1 further comprising a second oilfield apparatus, wherein the second oilfield apparatus is at times powered at least in part by excess electrical power generated by the second mover.
4 . The apparatus of claim 3 , further comprising a trailer onto which the first mover, the hybrid unit oilfield apparatus, the drivetrain, the second mover, or a combination thereof are mounted; and a truck coupled to the trailer, wherein the second mover is coupled to and receives energy from the truck.
5 . The apparatus of claim 3 , wherein the second oilfield apparatus comprises a well stimulation pump comprising a reciprocating pump.
6 . The apparatus of claim 3 , wherein the second oilfield apparatus is another hybrid oilfield apparatus of another hybrid unit comprising another first mover for generating first mechanical energy, wherein the another first mover comprises an internal combustion engine; the second oilfield apparatus; another drivetrain for providing the first mechanical energy from the first mover of the second hybrid unit to the second oilfield apparatus; and a second mover within the another drivetrain, wherein the second mover comprises another electric motor/generator, and generates and provides second mechanical energy to the second oilfield apparatus, generates electrical power, or a combination thereof; wherein the another drivetrain outputs the first mechanical energy and the second mechanical energy of the another hybrid unit directly to the second oilfield apparatus, the combined first and second mechanical energies of the another hybrid unit providing a torque sufficient to drive the second oilfield apparatus.
7 . The apparatus of claim 3 comprising a plurality of hybrid units, wherein the hybrid unit oilfield apparatus of each of the hybrid units is a same or different oilfield apparatus, and wherein the second mover of each of the hybrid units is operable to at times provide excess electrical power utilized to drive the second oilfield apparatus, a hybrid unit oilfield apparatus of another of the plurality of hybrid units, or a combination thereof.
8 . The apparatus of claim 1 , wherein the electric motor/generator of each of the one or the plurality of hybrid units is connected with a storage apparatus that stores electricity produced by the electric motor/generator thereof.
9 . The apparatus of claim 8 , further comprising a second oilfield apparatus, wherein the second oilfield apparatus is at times powered at least in part by the excess electrical power generated by the second mover, and further comprising a synchronization apparatus that synchronizes electricity from the electric motor/generators of each of the one or the plurality of hybrid units prior to storage in the storage apparatus, prior to use driving the second oilfield apparatus, subsequent storage in the storage apparatus and prior to use driving the second oilfield apparatus, or a combination thereof.
10 . The apparatus of claim 1 further comprising a second oilfield apparatus, wherein the second oilfield apparatus is at times powered at least in part by the excess electrical power generated by the second mover, wherein the second oilfield apparatus comprises a piece of oilfield equipment coupled with an electric motor, and wherein the second mover of the one or the plurality of hybrid units is electrically connected with the electric motor, whereby excess electrical power produced by the second mover can be utilized to power the electric motor.
11 . The apparatus of claim 1 further comprising a trailer upon which the first mover, the hybrid unit oilfield apparatus, the drivetrain, and the second mover are mounted.
12 . The apparatus of claim 1 , wherein the hybrid unit oilfield apparatus is an auxiliary, non-pump, apparatus selected from a blender, a wellbore services manifold trailer, a conveyor, a datavan or a combination thereof, and wherein an excess electrical power generated by the second mover is utilized at times to at least in part power a second hybrid unit oilfield apparatus comprising a pump.
13 . A system comprising:
one or a plurality of pumps;
a fluid manifold providing fluid communication between each of the one or the plurality of pumps and a wellbore; auxiliary equipment selected from a fluid management system, a datavan, a blender unit providing a source of treatment fluids to the one or the plurality of pumps, one or more conveyors for transporting one or more components of the treatment fluid to the blender unit, or another equipment;
one or a plurality of hybrid units, each hybrid unit comprising: a first mover for generating a first mechanical energy, wherein the first mover comprises an internal combustion engine; a hybrid unit oilfield apparatus; a drivetrain for providing the first mechanical energy from the first mover to the hybrid unit oilfield apparatus; and a second mover, wherein the second mover comprises an electric motor/generator, that generates and provides a second mechanical energy to the hybrid unit oilfield apparatus and generates electrical power, wherein the drivetrain outputs the first mechanical energy and the second mechanical energy directly to the hybrid unit oilfield apparatus, the combined first and second mechanical energies providing a torque sufficient to drive the hybrid unit oilfield apparatus;
wherein the hybrid unit oilfield apparatus of at least one of the one or the plurality of hybrid units comprises a well stimulation pump comprising a reciprocating pump, and wherein an auxiliary apparatus is at least in part powered at times by excess electrical power generated by the second mover, wherein the auxiliary apparatus is selected from a blender, a wellbore services manifold trailer, a conveyor, a datavan or a combination thereof.
14 . The system of claim 13 wherein the system further comprises a second oilfield apparatus that is powered at least in part by the excess electrical power generated by the second mover, wherein the hybrid unit oilfield apparatus comprises auxiliary equipment and the second oilfield apparatus comprises one pump of the plurality of pumps, wherein the hybrid unit oilfield apparatus comprises the one pump of the plurality of pumps and the second oilfield apparatus comprises auxiliary equipment, or wherein the hybrid unit oilfield apparatus comprises one pump of the plurality of pumps and the second oilfield apparatus comprises another pump of the plurality of pumps.
15 . The system of claim 14 , further comprising an energy storage device to store the excess electrical power; a synchronization device connected with the second mover, the energy storage device, or both and that synchronizes the excess electrical power prior to or subsequent storage in the energy storage device; or both.
16 . The system of claim 14 , wherein the one pump is the hybrid unit oilfield apparatus of a first of the plurality of hybrid units, and wherein the another pump is the hybrid unit oilfield apparatus of another hybrid unit of the plurality of hybrid units.
17 . A method comprising: with one or each of a plurality of hybrid units: generating a first mechanical energy with a first mover of the hybrid unit, which hybrid unit is mechanically coupled to a hybrid unit oilfield apparatus, wherein the first mover comprises an internal combustion engine; generating a second mechanical energy with a second mover of the hybrid unit, which second mover is mechanically coupled to the hybrid unit oilfield apparatus, wherein the second mover comprises an electric motor/generator that generates and provides a second mechanical energy to the hybrid unit oilfield apparatus and generates electrical power; operating the hybrid unit oilfield apparatus using the first mechanical energy and the second mechanical energy, and
wherein the hybrid unit oilfield apparatus of at least one of the one of the plurality of hybrid units comprises a well stimulation pump comprising a reciprocating pump, and wherein the method further comprises at times powering an auxiliary apparatus at least in part by excess electrical power generated by the second mover, wherein the auxiliary apparatus is selected from a blender, a wellbore services manifold trailer, a conveyor, a datavan or a combination thereof.
18 . The method of claim 17 further comprising, at times, producing excess electrical power with the generator of the electric motor/generator; and utilizing at least a portion of the excess electrical power to operate at least one other oilfield apparatus.
19 . The method of claim 18 , comprising the plurality of hybrid units, and wherein the at least one other oilfield apparatus is operated entirely via the excess electrical power produced via generators of the electric motor/generators of the second movers of the plurality of hybrid units; wherein the at least one other oilfield apparatus is operatively connected with a second oilfield apparatus prime mover, wherein the second oilfield apparatus prime mover comprises an electric motor, and wherein the electric motor/generator of the one or the plurality of hybrid units is connected to the electric motor, whereby the excess electrical power from the one or the plurality of hybrid units can power the electric motor; and/or wherein the at least one other oilfield apparatus is the hybrid unit oilfield apparatus of another of the plurality of hybrid units, whereby excess electrical power from the plurality of hybrid units can be distributed among the plurality of hybrid units to operate the hybrid unit oilfield apparatus thereof.
20 . The method of claim 17 , further comprising, at times, producing excess electrical power with the generator of the electric motor/generator; and synchronizing, storing, or synchronizing and storing the excess electrical power from one or more of the plurality of hybrid units.