Hydraulic Fracturing Arrangement and Blending System

This application claims priority to and benefit of U.S. patent application Ser. No. 18/336,480, entitled “HYDRAULIC FRACTURING ARRANGEMENT AND BLENDING SYSTEM,” filed Jun. 16, 2023, the contents of which are incorporated in their entirety for all purposes.

The present disclosure relates to systems and methods for fracturing operations and preparing fluids used in fracturing operations, and more particularly, to blenders for mixing liquid and solid particles to prepare a fracturing fluid.

Fracturing is an oilfield operation that stimulates production of hydrocarbons, such that the hydrocarbons may more easily or readily flow from a subsurface formation to a well. For example, a fracturing system may be configured to fracture a formation by pumping a fracturing fluid into a well at high pressure and high flow rates. Some fracturing fluids may take the form of a slurry including water, proppants, and/or other additives, such as thickening agents and/or gels. The slurry may be forced via one or more pumps into the formation at rates faster than can be accepted by the existing pores, fractures, faults, or other spaces within the formation. As a result, pressure builds rapidly to the point where the formation may fail and may begin to fracture. By continuing to pump the fracturing fluid into the formation, existing fractures in the formation are caused to expand and extend in directions farther away from a well bore, thereby creating flow paths to the well bore. The proppants may serve to prevent the expanded fractures from closing when pumping of the fracturing fluid is ceased or may reduce the extent to which the expanded fractures contract when pumping of the fracturing fluid is ceased. Once the formation is fractured, large quantities of the injected fracturing fluid are allowed to flow out of the well, and the production stream of hydrocarbons may be obtained from the formation.

Systems for successfully completing a fracturing operation can be extensive and complex, as shown in, for example. Water from tanksand gelling agents dispensed by a chemical unitare mixed in a hydration unit. The discharge from hydration unit, along with sand carried on conveyorsfrom sand tanks, is fed into a blending unit. Blending unitmixes the gelled water and sand into a slurry. The slurry is discharged through low-pressure hoseswhich convey it into two or more low-pressure linesin a frac manifold. The low-pressure linesin frac manifoldfeed the slurry to an array of pumps, perhaps as many as a dozen or more, through low-pressure “suction” hoses. The chemical unit, hydration unitand blending unitmay be mounted on a trailer that may be transported by trucks.

Pumpstake the slurry and discharge it at high pressure through individual high-pressure “discharge” linesinto two or more high-pressure lines or “missiles” on frac manifold. Missiles flow together, i.e., they are manifolded on frac manifold. Several high-pressure flow linesrun from the manifolded missiles to a “goat head”. Goat headdelivers the slurry into a “zipper” manifold(also referred to by some as a “frac manifold”). Zipper manifoldallows the slurry to be selectively diverted to, for example, one of two well heads. Once fracturing is complete, flow back from the fracturing operation discharges into a flowback manifoldwhich leads into flowback tanks.

Typically, hydraulic fracturing blenders utilize a single suction pump, tub, and discharge pump. If one of the components has a failure, the entire blender must be shut down and, in turn, the entire fracturing operation. This may lead to costly downtime and even cause the well to be sanded. This occurs when the operation cannot flush the well and sand is left in the wellbore. If enough sand is left in the wellbore, fracturing operations cannot continue until the sand is flushed out using coiled tubing or a service rig. A drop in the boost pressure in the pumps also may cause cavitation, which may lead to failures such as fluid end cracking and power failure.

The present disclosure generally is directed to configurations of multi-blender systems that include a plurality of independently operable blender units each having components that can operate with either blender unit. The multi-blender systems can operate with separate pumps, such as centrifugal pumps, to provide a plurality of operational states for each pump within a fleet of pumps or within multiple fleets of pumps, such as during simultaneous hydraulic fracturing operations. In some of the disclosed configurations, the multi-blender system can segment a fleet of pumps into clean pumps, which receive a clean stream having a minimal amount of solids, and dirty pumps, which receive a dirty stream having solid particulates, to increase the useful life of the fleet. In configurations in which a pump is configured to receive multiple, fluids the disclosed system can segment a single pump into clean cylinder and dirty cylinders to increase the useful life of the pump. Some of the disclosed configurations provide enhanced control of fluid delivery to source and can provide control of fluid properties, such as density and sand concentration, downstream of the blender.

Some aspects of the present disclosure can include a hydraulic fracturing system that includes a blender having a first blender unit configured to be in communication with a fleet of pumpers and a second blender unit configured to be in communication with the fleet of pumpers and a pump configured to deliver a third fluid to the fleet of pumpers. In some configurations, at least one pumper of the fleet of pumpers is configured to be in fluid communication with at least two of: first blender unit, second blender unit, or pump. The first blender unit can include a first tub having a first mixer configured to mix fluid and solid particulates, a first suction pump configured to deliver fluid to the first tub, and a first discharge pump configured to draw a first fluid from the first tub. Additionally, or alternatively, the second blender unit can include a second tub having a second mixer configured to mix fluid and solid particulates, a second suction pump configured to deliver fluid to the second tub, and a second discharge pump configured to draw a second fluid from the second tub. In some configurations, the first blender unit and the second blender unit are disposed on the same trailer.

Some of the disclosed systems can include a plurality of crossover lines configured to provide selective fluid communication between the first blender unit and the second blender unit such that the second discharge pump is configured to draw the second fluid from the second tub and the first discharge pump is configured to draw the first fluid from the first tub. In some configurations, the first fluid from the first blender unit and the third fluid from the pump are configured to be mixed prior before being received at the at least one pumper. The system can include a first proppant transport system configured to deliver proppant to the first tub, a second proppant transport system configured to deliver proppant to the second tub, one or more water tanks configured to deliver water to the pump, or combination thereof.

In some aspects, the system can include a controller configured to be in communication with the first blender unit, second blender unit, and pump. The controller can be configured to operate the system in a first state in which the first blender unit delivers the first fluid to a first set of pumpers of the fleet of pumpers, the second blender unit delivers the second fluid to a second set of pumpers of the fleet of pumpers, and the pump delivers the third fluid to a third set of pumpers of the fleet of pumpers. In some such configurations, the first fluid includes solid particulates, and the second fluid and the third fluid are clean fluids substantially free of solid particulates. In some aspects, based on a failure, the controller is configured to operate the system in a second state in which the second blender unit delivers a fourth fluid having solid particulates to at least one of the second set of pumpers, the pump delivers the third fluid to the third set of pumpers.

Some of the disclosed configurations include the fleet of pumpers fluidly connected to a first well and a fleet of second pumpers fluidly connected to a second well. In such configurations, the second blender unit and the pump can be configured to be in communication with the fleet of second pumpers. The controller can be configured to operate the system in a third state in which the first blender unit delivers the first fluid to a first set of pumpers of the fleet of pumpers, the pump delivers the third fluid to a second set of pumpers of the fleet of pumpers, the second blender unit delivers the second fluid to a first set of pumpers of the fleet of second pumpers, and the pump delivers the third fluid to a second set of pumpers of the fleet of second pumpers. In some such configurations, the first fluid and the second fluid include solid particulates and the third fluid is a clean fluid substantially free of solid particulates. In some aspects, based on a failure, the controller is configured to operate the system in a fourth state in which the second blender unit delivers the second fluid to the first set of pumpers of the fleet of pumpers and the first set of pumpers of the fleet of second pumpers. In some of the systems disclosed herein, the pump can include one or more centrifugal pumps. Some of the disclosed systems can include a pumper having a first set of plungers associated with the first fluid end and a second set of plungers associated with the second fluid end, wherein the first set of plungers have a stroke length less than a stroke length of the second set of plungers.

Some of the disclosed aspects include a method for blending liquid and solid particulates together in a split streaming operation, a simultaneous fracturing operation, or both. Some of the methods can include operating a blender in a first state, operating a pump in a first state, and switching an operation state of the blender from the first state to a second state. In some such methods, operating the blender in the first state may include pumping a first fluid through a first blender unit to a first set of pumpers; the first blender unit having a first tub mixer, a first discharge pump, and a plurality of first discharge ports and pumping a second fluid through a first blender unit to a first set of pumpers; the first blender unit having a first tub mixer, a first discharge pump, and a plurality of first discharge ports. In the first state, the first fluid may not be pumped through the second blending unit. In some such methods, operating the pump in the first state can include pumping a third fluid to the second set of pumpers or to a third set of pumpers. Operating the blender in the second state may include pumping the first fluid to at least one pumper of the second set of pumpers or third set of pumpers.

In some methods the first fluid includes a mixing fluid and solid particulates, and the second and third fluids are substantially free of solid particulates. In some of the disclosed configurations, while the blender is in the second state, the method can include pumping the first fluid from the first tub mixer, to the second discharge pump, and to the plurality of second discharge ports. The first set of pumpers can be connected to a first well and the second set of pumpers can be connected to a second well. In other configurations, the first set of pumpers and the second set of pumpers are connected to a first well. In some methods, the pump includes one or more centrifugal pumps.

Some aspects of the present disclosure can include a blender, a centrifugal pump, and a pumper. The blender can include a first blender unit and a second blender unit disposed on a platform. The first blender unit may include a first tub having a first mixer configured to mix fluid and solid particulates, a first suction pump configured to deliver fluid to the first tub, a first discharge pump configured to draw a first fluid from the first tub, or combination thereof. The second blender unit may include a second tub having a second mixer configured to mix fluid and solid particulates, a second suction pump configured to deliver fluid to the second tub, a second discharge pump configured to draw a second fluid from the second tub. In some of the disclosed configurations, the centrifugal pump configured to pump a third fluid and the pumper may include a first fluid end and a second fluid end. In some such configurations, the first fluid end is in fluid communication with the first blender unit and the second fluid end is in fluid communication with the second blender unit or the centrifugal pump. The system can include a first set of plungers associated with the first fluid end and a second set of plungers associated with the second fluid end. In some aspects, the first set of plungers have a stroke length less than a stroke length of the second set of plungers.

The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are “coupled” may be unitary with each other. The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. The term “substantially” or “approximately” is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed configuration, the term “substantially” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 5, and 10 percent.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”), and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, something that “comprises,” “has,” “includes,” or “contains” one or more elements possesses those one or more elements but is not limited to possessing only those one or more elements. Likewise, a method that “comprises,” “has,” “includes,” or “contains” one or more steps possesses those one or more steps but is not limited to possessing only those one or more steps.

Furthermore, all numerical ranges herein should be understood to include all integers, whole or fractions, within the range, inclusive of the ends of the ranges. Moreover, these numerical ranges should be construed as providing support for a claim directed to any number or subset of numbers in that range. For example, a disclosure of from 1 to 10 should be construed as supporting a range of from 1 to 8, from 3 to 7, from 1 to 9, from 3.6 to 4.6, from 3.5 to 9.9, and so forth. Additionally, the use of between when describing two endpoints of a numerical range should be understood to include those endpoints. For example, a disclosure of between 1 to 10 should be construed as supporting a range including 1 and including 10.

Herein, “or” is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context, and can have the same meaning as “and/or.” Therefore, herein, “A or B” means “A, B, or both,” unless expressly indicated otherwise or indicated otherwise by context. Moreover, “and” is both joint and several, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A and B” means “A and B, jointly or severally,” unless expressly indicated otherwise or indicated otherwise by context.

Any configuration of any of the apparatuses, systems, and methods can consist of or consist essentially of—rather than comprise/include/have—any of the described steps, elements, or features. Thus, in any of the claims, the term “consisting of” or “consisting essentially of” can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb.

The feature or features of one configuration may be applied to other configurations, even though not described, or illustrated, unless expressly prohibited by this disclosure or the nature of the configurations. Further, an apparatus or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described. Some details associated with the configurations described above and others are described below.

Additional features and advantages of the disclosed method and apparatus are described in, and will be apparent from, the following Detailed Description and the Figures. The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the figures and description. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter.

The present disclosure will now be described more fully hereinafter with reference to example configurations thereof with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. These example configurations are described so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those skilled in the art. Features from one configuration or aspect may be combined with features from any other configuration or aspect in any appropriate combination. For example, any individual or collective features of method aspects or configurations may be applied to apparatus, product, or component aspects or configurations and vice versa. The disclosure may be embodied in many different forms and should not be construed as limited to the configurations set forth herein; rather, these configurations are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification and the appended claims, the singular forms “a,” “an,” “the,” and the like include plural referents unless the context clearly dictates otherwise. In addition, while reference may be made herein to quantitative measures, values, geometric relationships or the like, unless otherwise stated, any one or more if not all of these may be absolute or approximate to account for acceptable variations that may occur, such as those due to manufacturing or engineering tolerances or the like.

Referring now to, a wellsite hydraulic fracturing pumper systemis shown. The wellsite hydraulic fracturing pumper systemcan includes a plurality of mobile power unitsarranged around a wellheadto supply the wellheadwith high-pressure fracturing fluids as will be understood by those skilled in the art. Mobile power unitscan drive one or more hydraulic fracturing pumpsthat discharge high pressure fluid to a manifoldsuch that the high pressure fluid is provided to the wellhead.

Fracturing pumpsmay be suitable for pumping any one or more fluid(s) for hydraulic fracturing. In some configurations, the pumpsare capable of providing a higher pumping capacity while still having physical dimensions enabling transportation of the mobile power unitsincluding the hydraulic fracturing pump on public highways. Each of the hydraulic fracturing pumpscan be driven by a prime mover, such as a gas turbine engine, electric motor, internal combustion engine (e.g., diesel engine), or the like.

In some configurations, the wellsite hydraulic fracturing pumper systemcan include a plurality of mobile power unitsalso arranged around or proximate to the wellhead. The mobile power unitscan drive an electrical generatorthat provides electrical power to the wellsite hydraulic fracturing pumper system. In other configurations, such as configurations which require a combustible fuel, mobile power unitscan include one or more fuel supplies for supplying the prime movers and any other fuel-powered components of the hydraulic fracturing system, such as auxiliary equipment, with fuel. The fuel supplies may include gaseous fuels, such as compressed natural gas (CNG), natural gas, field gas, pipeline gas, methane, propane, butane, and/or liquid fuels, such as, for example, diesel fuel (e.g., #2 diesel), bio-diesel fuel, bio-fuel, alcohol, gasoline, gasohol, aviation fuel, and other fuels as will be understood by those skilled in the art. In some such configurations, electrical power can be generated or be delivered by other sources (e.g., power grids) known in the art.

As shown in, a blendercan provide a flow of fluid to the fracturing pumpswhich is pressurized by and discharged from the fracturing pumps into the manifold. Blendercan include one or more prime movers (e.g., electric motors) that are configured to power pumps that convey fluid or fluid mixtures to and from the blender. In some configurations, systemmay include one or more water tanksfor supplying water for fracturing fluid, one or more chemical additive unitsfor supplying gels or agents for adding to the fracturing fluid, one or more proppant tanks(e.g., sand tanks) for supplying proppants for the fracturing fluid, or combination thereof. Some configurations of systemcan include a hydration unitfor mixing water from the water tanksand gels and/or agents from the chemical additive unitsto form a mixture, for example, gelled water. Systemcan also include a one or more proppant transport system, such as screw conveyors, conveyor belts, sand augers, or the like, that deliver the proppant from proppant tanks.

In operation, blendercan receive a fluid, such as from hydration unit, and solid particles, such as proppants via proppant transport system. Blendermay mix the fluid (or fluid mixture) and the proppants into a slurry to serve as fracturing fluid for hydraulic fracturing system. Once combined, the slurry may be discharged through low-pressure hoses, which convey the slurry into low-pressure lines in fracturing manifold. In the example shown, the low-pressure lines in the fracturing manifoldmay feed the slurry to the hydraulic fracturing pumpsthrough low-pressure suction hoses as will be understood by those skilled in the art. Fracturing pumpsdischarge the slurry (e.g., the fracturing fluid including the water, agents, gels, and/or proppants) at high flow rates and/or high pressures to fracturing manifoldand, in some configurations, the fracturing pumps may discharge the slurry through individual high-pressure discharge lines into two or more high-pressure flow lines, sometimes referred to as “missiles.” The fluid can then be delivered from the fracturing manifoldinto the wellhead, such as via a wellhead manifold or wellhead assembly as is understood in the art.

The wellsite hydraulic fracturing pumper systemcan include a supervisory control unit that monitors and controls operation of the mobile power unitsdriving the fracturing pumps, the mobile power unitsdriving electrical generators, the blender, or other units, and may be referred to generally as controller. Although described as a single controller, controllercan include a plurality of distinct controllers (e.g., processors, memories, transceivers, and the like) cooperating together to perform the functions described herein. For example, controllermay be a mobile control unit in the form of a trailer or a van, as appreciated by those skilled in the art. In some configurations, all of the hydraulic fracturing pumpsare controlled by the controllersuch that to an operator of the controller, the hydraulic fracturing pumps are controlled as a single pump or pumping system; however, in other configurations, the fracturing pumpscan be controlled individually or in any other manner disclosed in the art. Further details regarding the supervisory control unit are disclosed in U.S. application Ser. No. 17/182,408 filed on Feb. 23, 2021, and U.S. application Ser. No. 17/189,397 filed on Mar. 2, 2021, which are hereby incorporated by reference in their entireties.

illustrates a schematic of a control system for the wellsite hydraulic fracturing pumper systemreferred to generally as a control system. As depicted, control systemcan include controllerwhich is configured to control one or more operations of system, such as, but not limited to, operation of the flow of fluid and other materials through blender, pumps, or the like, such as operation of inlets or outlets, monitoring of flow parameters, fluid compositions, or the like (e.g., via sensors or other controllers), or combination thereof.

Controllermay include a processorcoupled to a memory(e.g., a computer-readable storage device). In some configurations, controllermay include one or more application(s)that access processorand/or memoryto perform one or more operations of system. Processormay include or correspond to a microcontroller/microprocessor, a central processing unit (CPU), a field-programmable gate array (FPGA) device, an application-specific integrated circuits (ASIC), another hardware device, a firmware device, or any combination thereof. Memory, such as a non-transitory computer-readable storage medium, may include volatile memory devices (e.g., random access memory (RAM) devices), nonvolatile memory devices (e.g., read only memory (ROM) devices, programmable read-only memory, and flash memory), or both. Memorymay be configured to store instructions, one or more thresholds, one or more data sets, or combination thereof. In some configurations, instructions(e.g., control logic) may be configured to, when executed by the one or more processors, cause the processor(s) to perform one or more operations (e.g., actuate valves based on inputs and outputs of the vessels). The one or more thresholdsand one or more data setsmay be configured to cause the processor(s) to generate control signals (e.g.,). For example, the processor(s)may initiate and/or perform operations as described herein. As a specific example, thresholds can include a volume level of a tub, a concentration of a material (e.g., sand, chemical, additive, or the like) within the fluid, a time, a pressure, a temperature, a flow rate, or other fluid parameter within the system, pump rpm (e.g., maximum or minimum allowable rotational rate), prime mover rpm, screen out threshold, or other thresholds. Data setscan include data associated with thresholds or other parameters of system, such as, operational data, maintenance data, equipment set up, equipment alarm history, prime mover information, equipment health ratings, or the like.

Application(s)may communicate (e.g., send and/or receive) with processorand memory. For example, application(s)may receive data from sensor(s) or memory(e.g., data sets), manipulate or organize the data, and send a signal to processorto cause the processor to output the data (e.g., via interfaceor I/O device) or store the data (e.g., via memory). In some configurations, application(s)comprises COMSOL, ABAQUS, ImageJ, Matlab, Solidworks, AutoCAD, ANSYS, LabView, CATIA, OpenFoam, HFSS, Mathcad, combination thereof, or the like.

In the depicted configuration, control systemmay comprise one or more interface(s), one or more I/O device(s), and a power sourcecoupled to controller. Systemcan include one or more sensor(s) configured to detect one or more parameters and to provide data to controller(e.g., via control signal). Each component of control systemcan be in signal communication with one or more other components of the control system, which can be a wired connection or a wireless connection. In some configurations, circuitry (e.g., a PCB, wires, etc.) may connect components of control systemwith one or more other components of system. Additionally, or alternatively, components of control systemmay be in wireless communication with one or more other components of systemsuch as, for example, via be Wi-Fi®, Bluetooth®, ZigBee, or forms of near field communications. In some configurations, components may be in signal communication via one or more intermediate controllers or relays that are in signal communication with one another. For example, a pump output pressure transducer may be in direct electrical communication with a pump controller and the pump controller may be in direct electrical communication with a controller of the mobile power unitwhich is in communication with the controller.

Interfacesmay include a network interface and/or a device interface configured to be communicatively coupled to one or more other devices. For example, interfacesmay include a transmitter, a receiver, or a combination thereof (e.g., a transceiver), and may enable wired communication, wireless communication, or a combination thereof, such as with I/O device. The I/O device(s)may include a touchscreen, a display device, a light emitting diode (LED), a speaker, a microphone, a camera, keyboard, computer mouse, another I/O device, or any combination thereof, as illustrative, non-limiting examples. In some configurations, interfaces(s)and/or I/O device(s)may enable a wired connection to controllervia a port or other suitable configuration.

Power sourcemay be coupled to controller, interface(s), I/O device(s), or combination thereof. In some configurations, power sourcemay be coupled to components of control systemvia circuitry. In some configurations, power sourcemay include a battery, generator (e.g.,), electrical grid, or the like. Although systemhas been described as including interface(s), I/O device(s), and power source, in other configurations, the system may not include one or more of the interface(s), I/O device(s), or power source.

Controlleris configured to generate and send control signals. For example, controllermay generate and/or send control signalsresponsive to receiving a signal and/or one or more user inputs via the one or more interfacesand/or the one or more I/O devices. Additionally, or alternatively, controllermay generate and/or send control signalsresponsive to one or more of instructions, thresholds, or data sets, or receiving a control signal from one or more components of system, such as, pumps, blender, generator, or controllers thereof, sensors, or other components.

The controllermay be in signal communication with the blender(or controller thereof) to control the delivery of the proppant to the blender and a flow rate of fluids to or from the blender. In some configurations, the controllermay be in signal communication with the fracturing pumps(or controller thereof) to control a discharge rate of fluid from the fracturing pumps into the manifold. In addition, the controllermay be in signal communication with one or more sensors of the wellsite hydraulic fracturing pumper systemto receive measurements or data with respect to the fracturing operation. For example, the controllercan receive a measurement of pressure of the fluid being delivered to the wellheadfrom a wellhead pressure transducer, a manifold pressure transducer, or a pump output pressure transducer. The wellhead pressure transducercan be disposed at the wellheadto measure a pressure of the fluid at the wellhead. The manifold pressure transduceris shown at an end of the manifold. However, as understood by those skilled in the art, the pressure within the manifoldis substantially the same throughout the entire manifold such that the manifold pressure transducermay be disposed anywhere within the manifold to provide a pressure of the fluid being delivered to the wellhead. The pump output pressure transducercan be disposed adjacent an output of one of the fracturing pumpswhich is in fluid communication with the manifoldand thus, the fluid at the output of the fracturing pumps is at substantially the same pressure as the fluid in the manifold and the fluid being provided to the wellhead. At least some of (e.g., up to and including all of) the fracturing pumpsmay include a pump output pressure transducerand the controllermay calculate the fluid pressure provided to the wellheadas an average of the fluid pressure measured by each of the pump output pressure transducers. In some configurations, controllermay be in signal communication with one or more other sensors such as tub level sensors, pressure sensors, magnetic pickups, power draw sensors, or the like.

In some configurations, the controllermay be in signal communication with sensors disposed about the blender. For example, the blendermay include a blender controller that is configured to perform one or more operations or transmit one or more signals with respect to the components of the blender or other sub-units of system, such as a flow meter, encoder, or pickup. For example, controllercan receive data, such as a rotation rate or feed rate of the proppant transport system(e.g., screw conveyors, belt conveyors, or other suitable solids transport system) or other information to determine an amount of proppant delivered to blender, a flow rate of fluid going into or out of the blender, or the like.

In some configurations, instructions(e.g., control logic) may be configured to, when executed by the one or more processors, cause the processor(s) to perform one or more operations. For example, the one or more operations may include receiving a message (e.g., control signal, a command, or an instruction) to perform an operation and identifying the requested operation. To illustrate, the operation may include controlling the flow of fluid, additives, or mixed fluid in a multi-blender system (e.g.,). For example, one or more operations may include actuating one or more valves, such as a crossover valve, to transmit the fluid between two blending units, adjusting (e.g., reducing or stopping) a speed of a first pump of a first blending unit, and adjusting (e.g., increasing) the speed of a second pump of a second blending unit. The one or more operations may also include transmitting or receiving one or more signalsto one or more other components, such as one or more pumpsor controller thereof, generatoror controller thereof, mobile power units,, or controller thereof. In some configurations, operations can include receiving data such as pump information, operational data, maintenance data, equipment set up, equipment alarm history, prime mover information and equipment health ratings.

Referring now to, shown are various views of a blender(e.g., multi-blender system) which can be utilized in hydraulic fracturing operations, such as those described herein. In some configurations, blendercan include or correspond to blenderof. Blenderis configured to mix fluid (e.g., from a hydration unit) with one or more additives (e.g., from a sand transport system, chemical additive unit, dry additive unit, or the like) and deliver the fluid to one or more other components (e.g., pumps) in the fracturing system. In the depicted configuration, blenderincludes two separate blender units each configured to be controllable independent of one another as described herein. Each blender unit can be coupled to a power source, such as a generator, to transfer fluid between components of the hydraulic fracturing system and can be utilized for operation in single hydraulic fracturing operations and simultaneous hydraulic fracturing operations.

Blendermay include a first blender unit and a second blender unit positioned adjacent each other on the same trailer (e.g., as shown in). First blender unit can include a first inlet manifold, a first suction pump, a first tub, a first discharge pump, and a first outlet manifold. Additionally, or alternatively, second blender unit can include a second inlet manifold, a second suction pump, a second tub, a second discharge pump, and a second outlet manifold

First inlet manifoldincludes a plurality of ports that are configured to be fluidly coupled to one or more fluid sources. In an illustrative configuration, ports of first inlet manifoldcan be coupled to an outlet of a hydration unit (e.g.,), water tanks (e.g.,), or other fluid source. First inlet manifoldis configured to be in fluid communication with first suction pumpthat is configured to deliver fluid from respective inlet ports to first tubor second tub. For example, in some configurations, first suction pumpis configured to deliver fluid exclusively to first tuband, in other configurations, the first suction pump is configured to deliver fluid to second tubvia a crossover line(e.g., via actuation of a crossover valve).

First outlet manifoldincludes a plurality of ports that are configured to be fluidly coupled to one or more components to deliver mixed fluid or slurry, such as fracturing pumps (e.g.,), a manifold (e.g.,), the wellhead (e.g.,), or the like. First outlet manifoldis configured to be in fluid communication with first discharge pumpthat is configured to deliver fluid from first tubor second tubto ports of the first outlet manifold. For example, in some configurations, first discharge pumpis configured to deliver fluid exclusively from first tubto first outlet manifoldand, in other configurations, the first discharge pump is configured to deliver fluid from second tubto the first outlet manifold via a crossover line(e.g., via actuation of a crossover valve). Each of first suction pumpand first discharge pumpcan include a prime mover, such as a motor, that is configured to drive the pump and can be any suitable pump, such as a centrifugal pump.

First tubcan be configured to be in fluid communication with first inlet manifold, first suction pump, first discharge pump, first outlet manifold, second inlet manifold, second suction pump, second discharge pump, or second outlet manifolddepending on the operation of blender. First tubis configured to mix fluid and solid particulates and can include or be coupled to a mixer, such as a tub pump or a motor coupled to one or more paddles or other agitators. In some configurations, first tubis configured to be in fluid communication with a first proppant transport system that is separate from the proppant transport system of second tub. In some configurations, the mixer (e.g., mixing pump, paddle mixer, etc.) is separate from the suction and discharge pumps (e.g.,,) and can be configured to only to mix the fluid (e.g., slurry) and not pressurize or discharge the fluid. In such configurations, the rate of agitation in first tubmay be independent of a rate of discharge of fluid from the tub. This is contrary to the traditional mixing systems that integrate the mixing tub and the pump to save space and provide more compact blender. In the depicted configurations, by including crossover linebetween the tubs (e.g.,) and the discharge pumps (e.g.,) each pump can be configured to draw fluid from either mixing tub. Such configurations allow near instantaneous switching between mixing tubs and, in split streaming process, enable near instantaneous switching between a fluid-only tank and a slurry tank (e.g., to change slurry density or flush the well) without sacrificing pressure, flow rate, or other performance parameters. The components of second blender unit (e.g.,,,,) can be configured similarly to the components of the first blender unit described above.

One or more crossover linesare disposed between components of the first and second blender units. For example, a crossover line can be disposed between the first and second tubs,and first and second discharge pumps,. In some configurations, a crossover linecan be posited between first inlet manifoldand second inlet manifold, between first outlet manifoldand second outlet manifold, or both. Additionally, or alternatively, a crossover linecan be disposed between the first and second tubs,and first and second suction pumps,. In this way and others, the components of the first and second blender units can be operated both independently and interchangeably as described in further detail in U.S. application Ser. No. 17/807,658 filed on Jun. 17, 2022, which is hereby incorporated by reference in its entirety.

Each blender unit can be operated via the control systems (e.g.,) described herein and can be configured to provide redundancy in the event one of the blender units fails or to use different fluid mixtures (or concentrations thereof) for different pumps, such as during split streaming operations. The control system can actuate one or more valves, pumps, or motors, to control the flow of fluid and additives within blender. For example, control system can operate each of first and second blending unit independently during normal operations. To further illustrate, the first blending unit can be configured to provide different sand concentrations, a different amount of fluid volumes, different chemical loadings, different treatment schedules, as compared to the second blending unit. In some configurations, such as during failure of one of the blending units, the control system can be configured to operate the remaining blending unit while the unactive blending unit is repaired or replaced. In configurations in which the blending units are operating for different well sites (e.g., in simultaneous fracturing operations), a single blending unit can be utilized to temporarily supply the required fluid mixture to both well sites until operations can be stopped or the other blending unit can be repaired.

To further illustrate the operation of blender,depicts a schematic operation diagram of the blender. As described herein, blendercan define a plurality of different flow paths between each of the components of the first and second blending units and control system can adjust the flow path based on data or other operations described herein. In some such operations, it possible to run two different sand concentrations on the same blender at any given time. For example, while a first blender is running a certain concentration of sand, a second blender could be run without sand, such as a water mixed with a chemical. In some hydraulic fracturing operations, a group of pumps at a wellsite will pump sand on a first side (e.g., the dirty side) and a group of pumps will only pump fresh water on a second side (e.g., the clean side), also known as split streaming. Each blender of the multi-blender system (e.g.,) described herein can operate as both clean and dirty sides and can be configured to maintain split stream operations in the event of a failure of one of the blenders and maintain operation integrity in the event of a component failure.

As shown in, blendercan include a plurality of valves that can be actuated by control system to direct the flow path of fluid between the inlet manifolds (e.g.,), suctions pumps (e.g.,), tubs (e.g.,), discharge pumps (e.g.,), and outlet manifolds (e.g.,) . . . As depicted, blendercan be able to operate multiple blending units independently while also providing redundancy to operate each blending unit. For example, fluid can be drawn from first inlet manifold, to first suction pumpor to second suction pumpvia a first crossover line. In some configurations, fluid can be drawn from second inlet manifoldto second suction pumpor to first suction pumpvia the first crossover line. Fluid from first suction pumpcan then transferred to an inlet of first tubor to an inlet of second tubvia a second crossover line. For example, the piping between first suction pumpcan extend to both first tuband second tuband the flow path can be controlled via actuation of valves. In some configurations, fluid from second suction pumpcan be transferred to an inlet of second tubor to an inlet of first tubvia the second crossover line. Fluid from first tubcan be drawn to first discharge pumpor second discharge pumpvia a third crossover line and fluid from second tubcan be drawn to the second discharge pump or the first discharge pump via the third crossover line. Fluid from first discharge pumpcan then be transferred to first outlet manifoldor second outlet manifoldvia a fourth crossover line or fluid from second discharge pump can be transferred to the second outlet manifold or the first outlet manifold via the fourth crossover line.

Referring now tois an example of a hydraulic fracturing pumper systemfor delivering fluid into a wellbore. Systemincludes a multi-blender systemthat is configured to deliver a fluid (e.g., water or slurry) to a fleet of pumpersthat are configured to inject the fluid into wellbore. Blenderincludes a first blender unitand a second blender unitconfigured to operate independently of one another, as described herein. Each of first and second blender units,can be disposed on the same platform (e.g., trailer, truck, or other platform). In some configurations, systemcan include one or more additional pumpsconfigured to deliver a fluid to pumpers. For example, pumpmay be coupled to a clean fluid source (e.g.,) and is configured to deliver non-abrasive fluid to pumpers. In some configurations, pumpcan include one or more centrifugal pumps, however, other suitable pumps can be employed. Pumpcan be connected directly to one or more pumpers or can be connected to a fluid line downstream of the blender units (e.g.,,) to change the fluid properties after discharge from the blender units (e.g., to control the sand concentration or fluid density downstream of the blender). Although not shown for the sake of clarity, systemcan include one or more additional components, such as the components shown in system. In some configurations, systemcan include or correspond to system, such as, for example, blendercan include or correspond to blenderor blenderand pumperscan include or correspond to power unitsand pumps.

As depicted, systemincludes eight pumpersconfigured to deliver fluid to wellboreat flowrates and pressures sufficient to perform hydraulic fracturing as understood in the art; however, it should be understood that any other suitable number of pumpers can be used to perform the operations described herein. The pumperscan be configured or operated to receive a clean fluid (non-abrasive fluid that is substantially free of solid particulates—e.g., less than 5, 4, 3, 2, or 1% of solids by volume) or a dirty fluid (abrasive fluid-such as fluid mixed with proppant). Each pumpercan be configured to receive a fluid from one of first blender unit, second blender unit, pump, or combination thereof. In some configurations, at least one pumper(up to and including all pumpers) is coupled to at least two of: first blender unit, second blender unit, or pump. In such configurations, pumpercan include or be coupled to one or more valves that may be actuated to selectively switch between receiving fluid from the first blender unit, second blender unit, or pump. To illustrate, a pumper (e.g.,) can be coupled to first blender unitand pumpand systemcan be controlled such that the pumper can receive fluid from either first blender unitor pump. Some configurations may be further be able to selectively receive two fluid sources simultaneously, such as from both the first blender unit and the pump. In this way and others, a fluid source of pumperscan be more actively controlled as compared to traditional systems. Additionally, or alternatively, the sand concentration of blendercan be quickly increased by actuating one or more valves on the blender or in the coupling to pumpers. This makes it possible to quickly control the proppant concentration as compared to the conventional method, in which it is necessary to switch out the tub or wait for the sand concentration in the tub to change.

Referring now to, systemis depicted during a split stream operation. In the split stream operation, a group of pumperswill pump dirty fluid on a first side (e.g., the dirty side) and a group of pumperswill pump clean fluid on a second side (e.g., the clean side). Althoughshows the systemas having two dirty pumpersand six clean pumpers, in alternative configurations the system may contain any appropriate number of dirty pumps and clean pumps, dependent on the hydraulic horsepower required by the well, the amount of proppant desired to be pumped, the required flow rate or pressure of the fluid to be delivered to the well, or other considerations. Clean pumpersmay have a much longer useful life as the pumps are not subject to abrasive media and will accumulate much less wear and other damage. Although dirty pumps (e.g.,) may be exposed to a greater concentration of abrasive media to obtain the same amount of proppant to be delivered to wellbore, the increased wear on the dirty pumps is outweighed by the extended life of the clean pumps as explained in U.S. application Ser. No. 11/754,776.