Electric or natural gas fired small footprint fracturing fluid blending and pumping equipment

Abstract

Methods and systems for integral storage and blending of the materials used in oilfield operations are disclosed. A modular integrated material blending and storage system includes a first module comprising a storage unit, a second module comprising a liquid additive storage unit and a pump for maintaining pressure at an outlet of the liquid additive storage unit. The system further includes a third module comprising a pre-gel blender. An output of each of the first module, the second module and the third module is located above a blender and gravity directs the contents of the first module, the second module and the third module to the blender. The system also includes a pump that directs the output of the blender to a desired down hole location. The pump may be powered by natural gas or electricity.

What is claimed is: 
     
       1. An integrated material blending and storage system comprising:
 a storage unit;   a blender located under the storage unit;   wherein the blender is operable to receive a first input from the storage unit through a hopper;   a liquid additive storage module having a first pump to maintain constant pressure at an outlet of the liquid additive storage module;   wherein the blender is operable to receive a second input from the liquid additive storage module; and   a pre-gel blender, wherein the pre-gel blender comprises at least a pre-gel storage unit resting on a leg, further wherein the pre-gel storage unit comprises a central core and an annular space, wherein the annular space hydrates the contents of the pre-gel blender;   wherein the blender is operable to receive a third input from the pre-gel blender;   wherein gravity directs the contents of the storage unit, the liquid additive storage module and the pre-gel blender to the blender;   a second pump; and   a third pump;   wherein the second pump directs the contents of the blender to the third pump; and   wherein the third pump directs the contents of the blender down hole;   wherein at least one of the second pump and the third pump is powered by one of natural gas and electricity.   
     
     
       2. The system of  claim 1 , wherein the storage unit comprises a load sensor. 
     
     
       3. The system of  claim 1 , wherein the pre-gel blender comprises:
 a feeder coupling the pre-gel storage unit to a first input of a mixer;
 a fourth pump coupled to a second input of the mixer; 
   wherein the pre-gel storage unit contains a solid component of a well treatment fluid;   wherein the feeder supplies the solid component of the well treatment fluid to the mixer;   wherein the fourth pump supplies a fluid component of the well treatment fluid to the mixer; and
 wherein the mixer outputs a well treatment fluid. 
   
     
     
       4. The system of  claim 3 , wherein the well treatment fluid is a gelled fracturing fluid. 
     
     
       5. The system of  claim 4 , wherein the solid component is a gel powder. 
     
     
       6. The system of  claim 4 , wherein the fluid component is water. 
     
     
       7. The system of  claim 3 , wherein the central core contains the solid component of the well treatment fluid. 
     
     
       8. The system of  claim 3 , wherein the well treatment fluid is directed to the annular space. 
     
     
       9. The system of  claim 3 , wherein the annular space comprises a tubular hydration loop. 
     
     
       10. The system of  claim 9 , wherein the well treatment fluid is directed from the mixer to the tubular hydration loop. 
     
     
       11. The system of  claim 3 , wherein the well treatment fluid is selected from the group consisting of a fracturing fluid and a sand control fluid. 
     
     
       12. The system of  claim 3 , further comprising a power source to power at least one of the feeder, the mixer and the pump. 
     
     
       13. The system of  claim 12 , wherein the power source is selected from the group consisting of a combustion engine, an electric power supply and a hydraulic power supply. 
     
     
       14. The system of  claim 13 , wherein one of the combustion engine, the electric power supply and the hydraulic power supply is powered by natural gas. 
     
     
       15. The system of  claim 1 , further comprising a load sensor coupled to one of the storage unit, the liquid additive storage module or the pre-gel blender. 
     
     
       16. The system of  claim 15 , further comprising an information handling system communicatively coupled to the load sensor. 
     
     
       17. The system of  claim 15 , wherein the load sensor is a load cell. 
     
     
       18. The system of  claim 15 , wherein a reading of the load sensor is used for quality control. 
     
     
       19. The system of  claim 1 , wherein the electricity is derived from one of a power grid and a natural gas generator set. 
     
     
       20. A modular integrated material blending and storage system comprising:
 a first module comprising a storage unit;   a second module comprising a liquid additive storage unit and a first pump for maintaining pressure at an outlet of the liquid additive storage unit; and   a third module comprising a pre-gel blender, wherein the pre-gel blender comprises at least a pre-gel storage unit resting on a leg, further wherein the pre-gel storage unit comprises a central core and an annular space, wherein the annular space hydrates the contents of the pre-gel blender;   wherein an output of each of the first module, the second module and the third module is located above a blender; and   wherein gravity directs the contents of the first module through a hopper, the second module and the third module to the blender;   a second pump;   wherein the second pump directs the output of the blender to a desired down hole location; and   wherein the second pump is powered by one of natural gas and electricity.   
     
     
       21. The system of  claim 20 , wherein each of the first module, the second module and the third module is a self erecting module. 
     
     
       22. The system of  claim 20 , wherein the third module comprises:
 a feeder coupling the pre-gel storage unit to a first input of a mixer;   a third pump coupled to a second input of the mixer;   wherein the pre-gel storage unit contains a solid component of a well treatment fluid;   wherein the feeder supplies the solid component of the well treatment fluid to the mixer;   wherein the third pump supplies a fluid component of the well treatment fluid to the mixer; and   wherein the mixer outputs a well treatment fluid.   
     
     
       23. The system of  claim 22 , wherein the well treatment fluid is directed to the blender. 
     
     
       24. The system of  claim 20 , wherein the blender mixes the output of the first module, the second module and the third module. 
     
     
       25. The system of  claim 20 , further comprising a fourth pump for pumping an output of the blender down hole. 
     
     
       26. The system of  claim 25 , wherein the fourth pump is selected from the group consisting of a centrifugal pump, a progressive cavity pump, a gear pump and a peristaltic pump. 
     
     
       27. A method of preparing a fluid for use in a subterranean operation, the method comprising:
 a) preparing a mixture comprising a gel powder and water using a mixer;   b) transferring the mixture to a pre-gel storage unit   c) allowing the gel powder to at least partially hydrate in the pre-gel storage unit to form a hydrated mixture;   d) transferring the hydrated mixture to a blender;   e) blending the hydrated mixture with at least one component in the blender to prepare the fluid;   f) using a transfer pump to transfer the fluid to a down hole pump; and   g) using the down hole pump to pump the fluid into a down hole location, wherein either natural gas or electricity, or both, is used to power the transfer pump, the down hole pump, or a combination thereof.   
     
     
       28. The method of claim 27 further comprising transporting a storage unit, the pre-gel storage unit, a liquid additive storage module, or a combination thereof to a job site where one or more of steps a) through g) are performed. 
     
     
       29. The method of claim 27 further comprising using a liquid additive storage module having an output located at an elevation higher than an input of the blender, wherein gravity at least partially directs the at least one component from the one liquid additive storage module to the blender. 
     
     
       30. The method of claim 27 further comprising transferring the at least one component from a storage unit to the blender. 
     
     
       31. The method of claim 27 further comprising transferring the at least one component from a liquid additive storage module to the blender. 
     
     
       32. The method of claim 31 further comprising circulating the at least one component in the liquid additive storage module using a pump to maintain constant pressure at a head of the liquid additive storage module. 
     
     
       33. The method of claim 27 wherein the pre-gel storage unit rests on at least one leg. 
     
     
       34. The method of claim 27 wherein the pre-gel storage unit comprises an annular space and a central core. 
     
     
       35. The method of claim 34 wherein the gel powder is allowed to at least partially hydrate in the annular space. 
     
     
       36. The method of claim 34 wherein the gel powder is stored in the central core. 
     
     
       37. The method of claim 27 wherein the pre-gel storage unit comprises a tubular hydration loop. 
     
     
       38. The method of claim 37 wherein the gel powder is allowed to at least partially hydrate in the tubular hydration loop. 
     
     
       39. The method of claim 37 wherein the tubular hydration loop is located in an annular space of the pre-gel storage unit. 
     
     
       40. The method of claim 27 wherein the electricity is obtained from an on-site generator, a natural gas generator set, a power grid, or a combination thereof. 
     
     
       41. The method of claim 27 wherein the natural gas is used to power a natural gas fired engine, and wherein the natural gas fired engine is used to power the transfer pump, the down hole pump, or a combination thereof. 
     
     
       42. The method of claim 27 wherein the natural gas is obtained from a field on which at least a portion of the subterranean operation is performed. 
     
     
       43. The method of claim 42 further comprising converting the natural gas to liquefied natural gas, wherein the liquefied natural gas is used to power the transfer pump, the down hole pump, or a combination thereof. 
     
     
       44. The method of claim 42 further comprising conditioning the natural gas. 
     
     
       45. The method of claim 44 wherein conditioning the natural gas comprises cleaning the natural gas, compressing the natural gas in one or more compressor stations, removing water from the natural gas, or a combination thereof. 
     
     
       46. The method of claim 27 wherein the hydrated mixture is transferred from the pre-gel storage unit to the blender using electricity. 
     
     
       47. The method of claim 46 wherein the hydrated mixture is transferred from the pre-gel storage unit to the blender using a pump powered by the electricity. 
     
     
       48. The method of claim 27 further comprising measuring a weight, a mass, a volume, or a combination thereof of the mixture or the hydrated mixture in the pre-gel storage unit with one or more electronic load sensors. 
     
     
       49. The method of claim 48 wherein the one or more electronic load sensors are powered by an on-site generator. 
     
     
       50. The method of claim 48 further comprising monitoring the weight, the mass, the volume, or a combination thereof of the mixture or the hydrated mixture in the pre-gel storage unit with an information handling system that is electronically coupled to the one or more electronic load sensors. 
     
     
       51. The method of claim 50 wherein the information handling system is powered by an on-site generator. 
     
     
       52. The method of claim 50 wherein the information handling system generates an alert when the weight, the mass, the volume, or a combination thereof of the mixture or the hydrated mixture in the pre-gel storage unit reaches a threshold level. 
     
     
       53. The method of claim 50 wherein the information handling system provides a real-time visual depiction of the weight, the mass, the volume, or a combination thereof of the mixture or the hydrated mixture in the pre-gel storage unit. 
     
     
       54. The method of claim 27 wherein the pre-gel storage unit is adapted to connect to a vehicle to lower, raise or transport the pre-gel storage unit. 
     
     
       55. The method of claim 54 wherein the pre-gel storage unit comprises a latch system to connect the pre-gel storage unit to the vehicle. 
     
     
       56. A method of preparing a fluid for use in a subterranean operation, the method comprising:
 a) transferring at least one component of the fluid to a blender;   b) blending the at least one component in the blender to prepare the fluid;   c) using a transfer pump to transfer the fluid to a down hole pump; and   d) using the down hole pump to pump the fluid into a down hole location, wherein natural gas obtained from a field on which the subterranean operation is being performed is used to power the transfer pump, the down hole pump, or a combination thereof.   
     
     
       57. The method of claim 56 further comprising transporting a storage unit, a pre-gel storage unit, a liquid additive storage module, or a combination thereof to a job site where one or more of steps a) through d) are performed. 
     
     
       58. The method of claim 56 further comprising using a liquid additive storage module having an output located at an elevation higher than an input of the blender, wherein gravity at least partially directs the at least one component from the liquid additive storage module to the blender. 
     
     
       59. The method of claim 56 further comprising transferring the at least one component from a storage unit to the blender. 
     
     
       60. The method of claim 56 further comprising transferring the at least one component from a liquid additive storage module to the blender. 
     
     
       61. The method of claim 60 further comprising circulating the at least one component in the liquid additive storage module using a pump to maintain constant pressure at a head of the liquid additive storage module. 
     
     
       62. The method of claim 56 further comprising transferring the at least one component from a pre-gel storage unit to the blender. 
     
     
       63. The method of claim 62 wherein the pre-gel storage unit rests on at least one leg. 
     
     
       64. The method of claim 62 wherein the pre-gel storage unit comprises an annular space and a central core. 
     
     
       65. The method of claim 64 wherein a gel powder is allowed to at least partially hydrate in the annular space to form the at least one component. 
     
     
       66. The method of claim 64 wherein a gel powder is stored in the central core. 
     
     
       67. The method of claim 62 wherein the pre-gel storage unit comprises a tubular hydration loop. 
     
     
       68. The method of claim 67 wherein a gel powder is allowed to at least partially hydrate in the tubular hydration loop to form the at least one component. 
     
     
       69. The method of claim 67 wherein the tubular hydration loop is located in an annular space of the pre-gel storage unit. 
     
     
       70. The method of claim 62 wherein the at least one component is transferred from the pre-gel storage unit to the blender using electricity. 
     
     
       71. The method of claim 70 wherein the at least one component is transferred from the pre-gel storage unit to the blender using a pump powered by the electricity. 
     
     
       72. The method of claim 62 further comprising measuring a weight, a mass, a volume, or a combination thereof of the at least one component in the pre-gel storage unit with one or more electronic load sensors. 
     
     
       73. The method of claim 72 wherein the one or more electronic load sensors are powered by an on-site generator. 
     
     
       74. The method of claim 72 further comprising monitoring the weight, the mass, the volume, or a combination thereof of the at least one component in the pre-gel storage unit with an information handling system that is electronically coupled to the one or more electronic load sensors. 
     
     
       75. The method of claim 74 wherein the information handling system is powered by an on-site generator. 
     
     
       76. The method of claim 74 wherein the information handling system generates an alert when the weight, the mass, the volume, or a combination thereof of the at least one component in the pre-gel storage unit reaches a threshold level. 
     
     
       77. The method of claim 74 wherein the information handling system provides a real-time visual depiction of the weight, the mass, the volume, or a combination thereof of the at least one component in the pre-gel storage unit. 
     
     
       78. The method of claim 62 wherein the pre-gel storage unit is adapted to connect to a vehicle to lower, raise or transport the pre-gel storage unit. 
     
     
       79. The method of claim 78 wherein the pre-gel storage unit comprises a latch system to connect the pre-gel storage unit to the vehicle. 
     
     
       80. The method of claim 56 wherein the natural gas is used to power a natural gas fired engine, and wherein the natural gas fired engine is used to power the transfer pump, the down hole pump, or a combination thereof. 
     
     
       81. The method of claim 56 further comprising converting the natural gas to liquefied natural gas, wherein the liquefied natural gas is used to power the transfer pump, the down hole pump, or a combination thereof. 
     
     
       82. The method of claim 56 further comprising conditioning the natural gas. 
     
     
       83. The method of claim 82 wherein conditioning the natural gas comprises cleaning the natural gas, compressing the natural gas in one or more compressor stations, removing water from the natural gas, or a combination thereof. 
     
     
       84. A method of preparing a fluid for use in a subterranean operation, the method comprising:
 a) placing a liquid additive storage module and a blender at a job site such that at least one output of the liquid additive storage module is located at an elevation higher than at least one input of the blender;   b) transferring a liquid additive from the liquid additive storage module to the blender, wherein gravity at least partially directs the liquid additive from the liquid additive storage module to the blender;   c) blending the liquid additive with at least one component in the blender to prepare the fluid;   d) using a transfer pump to transfer the fluid to a down hole pump; and   e) using the down hole pump to pump the fluid into a down hole location, wherein either natural gas or electricity, or both, is used to power the transfer pump, the down hole pump, or a combination thereof.   
     
     
       85. The method of claim 84 further comprising transporting a storage unit, a pre-gel storage unit, the liquid additive storage module, or a combination thereof to a job site where one or more of steps a) through e) are performed. 
     
     
       86. The method of claim 84 further comprising circulating the liquid additive in the liquid additive storage module using a pump to maintain constant pressure at a head of the liquid additive storage module. 
     
     
       87. The method of claim 84 further comprising transferring the at least one component from a storage unit to the blender. 
     
     
       88. The method of claim 84 further comprising transferring the at least one component from a pre-gel storage unit to the blender. 
     
     
       89. The method of claim 88 wherein the pre-gel storage unit rests on at least one leg. 
     
     
       90. The method of claim 88 wherein the pre-gel storage unit comprises an annular space and a central core. 
     
     
       91. The method of claim 90 wherein a gel powder is allowed to at least partially hydrate in the annular space to form the at least one component. 
     
     
       92. The method of claim 90 wherein a gel powder is stored in the central core. 
     
     
       93. The method of claim 88 wherein the pre-gel storage unit comprises a tubular hydration loop. 
     
     
       94. The method of claim 93 wherein a gel powder is allowed to at least partially hydrate in the tubular hydration loop to form the at least one component. 
     
     
       95. The method of claim 93 wherein the tubular hydration loop is located in an annular space of the pre-gel storage unit. 
     
     
       96. The method of claim 88 wherein the at least one component is transferred from the pre-gel storage unit to the blender using electricity. 
     
     
       97. The method of claim 96 wherein the at least one component is transferred from the pre-gel storage unit to the blender using a pump powered by the electricity. 
     
     
       98. The method of claim 88 further comprising measuring a weight, a mass, a volume, or a combination thereof of the at least one component in the pre-gel storage unit with one or more electronic load sensors. 
     
     
       99. The method of claim 98 wherein the one or more electronic load sensors are powered by an on-site generator. 
     
     
       100. The method of claim 98 further comprising monitoring the weight, the mass, the volume, or a combination thereof of the at least one component in the pre-gel storage unit with an information handling system that is electronically coupled to the one or more electronic load sensors. 
     
     
       101. The method of claim 100 wherein the information handling system is powered by an on-site generator. 
     
     
       102. The method of claim 100 wherein the information handling system generates an alert when the weight, the mass, the volume, or a combination thereof of the at least one component in the pre-gel storage unit reaches a threshold level. 
     
     
       103. The method of claim 102 wherein the information handling system provides a real-time visual depiction of the weight, the mass, the volume, or a combination thereof of the at least one component in the pre-gel storage unit. 
     
     
       104. The method of claim 88 wherein the pre-gel storage unit is adapted to connect to a vehicle to lower, raise or transport the pre-gel storage unit. 
     
     
       105. The method of claim 104 wherein the pre-gel storage unit comprises a latch system to connect the pre-gel storage unit to the vehicle. 
     
     
       106. The method of claim 84 wherein the electricity is obtained from an on-site generator, a natural gas generator set, a power grid, or a combination thereof. 
     
     
       107. The method of claim 84 wherein the natural gas is used to power a natural gas fired engine, and wherein the natural gas fired engine is used to power the transfer pump, the down hole pump, or a combination thereof. 
     
     
       108. The method of claim 84 wherein the natural gas is obtained from a field on which at least a portion of the subterranean operation is performed. 
     
     
       109. The method of claim 108 further comprising converting the natural gas to liquefied natural gas, wherein the liquefied natural gas is used to power the transfer pump, the down hole pump, or a combination thereof. 
     
     
       110. The method of claim 108 further comprising conditioning the natural gas. 
     
     
       111. The method of claim 110 wherein conditioning the natural gas comprises cleaning the natural gas, compressing the natural gas in one or more compressor stations, removing water from the natural gas, or a combination thereof.