Mobile Pump System

Abstract

A mobile pump system includes: a trailer movable by a vehicle; a first pump and a second pump mounted to the trailer and in fluid communication with an outlet configured to flow a fluid to a destination and with a fluid source; a power source mounted to the trailer and directly coupled to the first pump and/or the second pump, where the power source includes a turbine and/or a natural gas fired reciprocating engine; and a control system configured to: activate the second pump, with the first pump deactivated, with a flow rate of the mobile pump system below a first set point; in response to the flow rate of the mobile pump system reaching the first set point, activate the first pump; and deactivate the second pump, with the first pump activated, in response to the flow rate of the mobile pump system reaching a second set point, where the second set point is greater than or equal to the first set point.

The invention claimed is 
     
         1 . A mobile pump system, comprising:
 at least one trailer movable by a vehicle;   a plurality of pumps comprising a first pump and a second pump, wherein the first pump and the second pump are each mounted to the at least one trailer, wherein the first pump and the second pump are each in fluid communication with an outlet configured to flow a fluid from the mobile pump system to a destination and with a fluid source configured to hold a pumping fluid;   a power source mounted to the at least one trailer and directly coupled to the first pump and/or the second pump, wherein the power source comprises a turbine and/or a natural gas fired reciprocating engine; and   a control system configured to:
 activate the second pump, with the first pump deactivated, with a flow rate of the mobile pump system below a first set point to cause the second pump to pump the pumping fluid; 
 in response to the flow rate of the mobile pump system reaching the first set point, activate the first pump to cause the first pump to pump the pumping fluid; and 
 deactivate the second pump, with the first pump activated, in response to the flow rate of the mobile pump system reaching a second set point, wherein the second set point is greater than or equal to the first set point. 
   
     
     
         2 . The mobile pump system of  claim 1 , wherein the first pump is configured to pump fluid at a flow rate as low as 1.5 bpm and at a flow rate of up to 30 bpm, and
 wherein the second pump is configured to pump fluid a flow rate as low as 0.1 bpm.   
     
     
         3 . The mobile pump system of  claim 1 , wherein the first pump comprises a multi-stage centrifugal injection pump. 
     
     
         4 . The mobile pump system of  claim 1 , wherein the first pump comprises a pressure-balanced pump. 
     
     
         5 . The mobile pump system of  claim 1 , wherein the second pump comprises a positive displacement pump. 
     
     
         6 . The mobile pump system of  claim 5 , wherein the positive displacement pump is a reciprocating triplex or quintuplex pump. 
     
     
         7 . The mobile pump system of  claim 1 , wherein the control system comprises an electronic governor configured to control at least one of a rotational speed of the power source, a flow rate of the first pump and/or the second pump, and a pumping pressure of the first pump and/or the second pump. 
     
     
         8 . The mobile pump system of  claim 7 , wherein the electronic governor is configured to adjust the flow rate of the first pump and/or the second pump by an incremental amount as low as 0.1 bpm. 
     
     
         9 . The mobile pump system of  claim 1 , wherein the power source is directly coupled to the first pump, wherein the direct coupling comprises a non-variable, fixed ratio direct-coupled connection or a direct-coupled gear connection including a speed reducer. 
     
     
         10 . The mobile pump system of  claim 1 , wherein the second pump is powered by an electric motor receiving power generated by the power source. 
     
     
         11 . The mobile pump system of  claim 6 , wherein the control system is configured to initiate a start-up protocol by:
 activating the second pump, with the first pump deactivated, until the flow rate of the mobile pump system is at least 1.5 bpm; and   activating the first pump, while the second pump is still activated, once the flow rate of the mobile pump system is at the first set point, wherein the first set point is at least 1.5 bpm.   
     
     
         12 . The mobile pump system of  claim 1 , wherein the mobile pump system is not permanently installed at a site for performing a pressure pumping application. 
     
     
         13 . The mobile pump system of  claim 1 , wherein the power source is operated using field gas. 
     
     
         14 . The mobile pump system of  claim 1 , wherein the first pump and/or the second pump are configured to pump fluid at a pressure of 15,000 psi or greater. 
     
     
         15 . The mobile pump system of  claim 1 , further comprising a fluid storage tank mounted to the at least one trailer and a third pump mounted to the at least one trailer and in fluid communication with the fluid storage tank, the first pump, and the second pump, wherein the third pump is configured to pump fluid from the fluid storage tank to the first pump and/or the second pump. 
     
     
         16 . The mobile pump system of  claim 1 , wherein the pumping fluid is pumped to the outlet by the second pump and not the first pump with the flow rate of the mobile pump system below the first set point, and the pumping fluid is pumped to the outlet by the first pump and optionally the second pump with the flow rate of the mobile pump system at or above the first set point. 
     
     
         17 . A method for performing a pressure pumping application, comprising:
 positioning the mobile pump system of  claim 1  on a pump site.   
     
     
         18 . The method of  claim 17 , further comprising:
 activating the second pump, with the first pump deactivated, until the flow rate of the mobile pump system is at least 1.5 bpm; and   activating the first pump, while the second pump is still activated, once the flow rate of the mobile pump system is at the first set point, wherein the first set point is at least 1.5 bpm.   
     
     
         19 . The method of  claim 18 , further comprising:
 deactivating the second pump, while the first pump is still activated, once the flow rate flow rate of the mobile pump system is at the second set point.   
     
     
         20 . A mobile pump system, comprising:
 a trailer movable by a vehicle;   a plurality of pumps comprising a first pump and a second pump, wherein the first pump and the second pump are each mounted to the trailer, wherein the first pump and the second pump are each in fluid communication with an outlet configured to flow a pumping fluid from the mobile pump system to a destination and configured to be in fluid communication with a fluid storage tank configured to hold the pumping fluid, wherein the first pump comprises a pressure-balanced multi-stage centrifugal injection pump, wherein the second pump comprises a reciprocating triplex or quintuplex positive displacement pump;   a power source mounted to the trailer and directly coupled to the first pump, wherein the power source comprises a turbine and/or a natural gas fired reciprocating engine, wherein the direct coupling comprises a non-variable, fixed ratio direct-coupled connection or a direct-coupled gear connection including a speed reducer;   a third pump mounted to the trailer and configured to be placed in fluid communication with the fluid storage tank, wherein the third pump is in fluid communication with the first pump and the second pump, wherein the third pump is configured to pump the pumping fluid from the fluid storage tank to the first pump and/or the second pump and   a control system configured to:
 activate the second pump, with the first pump deactivated, with a flow rate of the mobile pump system below a first set point to cause the third pump to pump the pumping fluid from the fluid storage tank to the second pump which is configured to pump the pumping fluid to the outlet; 
 in response to the flow rate of the mobile pump system reaching the first set point, activate the first pump to cause the third pump to pump the pumping fluid from the fluid storage tank to the first pump which is configured to pump the pumping fluid to the outlet; and 
 deactivate the second pump, with the first pump activated, in response to the flow rate of the mobile pump system reaching a second set point, wherein the second set point is greater than or equal to the first set point.