GAS DISTRIBUTION TRAILER FOR NATURAL GAS DELIVERY TO ENGINES

Abstract

A fluid distribution apparatus includes a trailer having a central platform and one or more sets of wheels. The central platform may include two or more hose reels mounted thereto, each of the hose reels including a reel that is rotatable about a rotation axis and a fluid distribution hose windable around the reel. The rotation axis of each of the hose reels may be generally parallel to a longitudinal axis of the central platform. The central platform may also include a manifold coupled with each of the hose reels and couplable with an external fluid source, such as a natural gas fuel source. The manifold may provide fluid from the external fluid source to each of the fluid distribution hoses of the respective hose reels.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority benefit to U.S. Provisional Patent Application No. 61/798,768, filed Mar. 15, 2013, and entitled “Gas Distribution Trailer for Natural Gas Delivery to Engines,” the entire disclosure of which is incorporated herein by reference.

BACKGROUND

The following relates generally to gas distribution systems and, more specifically, to a portable gas distribution system configured to distribute fluid from a fluid source to a number of locations at a hydrocarbon well site.

Hydrocarbon well completion technology has evolved drastically over the last decade, increasing oil and gas reserves and improving well performance. One technique of well completion is to perforate with special “perf guns” in a hydrocarbon producing zone, often over 10,000 feet below the surface, and pump a combination of water and sand to fracture the producing zone and prop channels open to enable extraction of hyrdocarbons. As the technique has evolved, one effective and economic technique has proven to be high pressure, high volume hydraulic fracturing jobs (often called “frac'ing” or “pressure pumping”). The use of as many as twenty semi-truck mounted, diesel engine driven positive displacement pumps, often operating 24 hours per day, year round, has become a common occurrence to provide pumping required to operate such sites. Such operations can result in the consumption of relatively large quantities of diesel fuel.

As drilling and completion technology has developed, one result has been that natural gas production has increased, thus increasing the domestic supply and driving the market demand and price of the commodity. This has increased the attractiveness of utilizing natural gas as a fuel in operations of oil and gas drilling sites. Dual fuel (blending natural gas and diesel fuel on engine) has proven to be one viable solution in pressure pumping services to reduce the amount of diesel fuel consumed, reduce engine emissions, and reduce completion costs.

While many producers may desire to utilize natural gas in completion operations, a significant challenge with pressure pumping services is delivering sufficient quantities of natural gas at an acceptable flow rate on many different locations, all with different layouts, and with limited time to rig up and rig down equipment. Furthermore, it is desirable for a fuel delivery system in pressure pumping operations to be flexible and allow adjustment to each individual site. An adaptable fuel delivery system developed for pressure pumping operations can be utilized in many different operational areas, across industries where multiple engines need hydrocarbon delivery from a single source of fuel. To date, fuel delivery for this application has been in the form of steel, rigid pipe protected by a steel enclosure. Each section of pipe and protective covering can be bulky, heavy and has limited flexibility to adapt to changing locations. From the rigid pipe, there is a run of flexible pipe that is run from the rigid manifold to an engine that is to receive the fuel. Such fuel delivery techniques may be relatively inefficient and require significant resources to set up and modify.

SUMMARY

The described features generally relate to one or more improved systems, apparatuses, and/or methods, for fluid distribution utilizing a mobile fluid distribution platform. In some aspects, a fluid distribution apparatus includes a trailer having a central platform and one or more sets of wheels. The central platform may include two or more hose reels mounted thereto, each of the hose reels including a reel that is rotatable about a rotation axis and a fluid distribution hose windable around the reel. The rotation axis of each of the hose reels may be generally parallel to a longitudinal axis of the central platform. The central platform may also include a manifold coupled with each of the hose reels and couplable with an external fluid source, such as a natural gas fuel source. The manifold may provide fluid from the external fluid source to each of the fluid distribution hoses of the respective hose reels.

Further scope of the applicability of the described methods and apparatuses will become apparent from the following detailed description, claims, and drawings. The detailed description and specific examples are given by way of illustration only, since various changes and modifications within the spirit and scope of the description will become apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the nature and advantages of the present invention may be realized by reference to the following drawings. In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

FIG. 1 shows a front and right-side perspective view of a fluid distribution trailer according to various aspects of the disclosure;

FIG. 2 shows a front and left side perspective view of the fluid distribution trailer according to various aspects of the disclosure;

FIG. 3 shows a rear and left side perspective view of the fluid distribution trailer according to various aspects of the disclosure;

FIG. 4 shows a right side view of the fluid distribution trailer according to various aspects of the disclosure;

FIG. 5 shows a left side view of the fluid distribution trailer according to various aspects of the disclosure;

FIG. 6 shows a front view of the fluid distribution trailer according to various aspects of the disclosure;

FIG. 7 shows a rear view of the fluid distribution trailer according to various aspects of the disclosure;

FIG. 8 shows a top plan view of the fluid distribution trailer according to various aspects of the disclosure; and

FIG. 9 shows a diagram of a fluid distribution apparatus according to various aspects of the disclosure.

DETAILED DESCRIPTION

Techniques are described for gas distribution utilizing a portable distribution system that provides flexible and readily adaptable configurations for delivery of fuel from a fuel source to several locations at a particular site. The inventors of the present disclosure have recognized that, particularly with respect to completion operations at hydrocarbon drilling sites, pumps need to be oriented in a specific and consistent manner at each location. Such pumps are often mounted on trucks, or trailers, are use internal combustion engines to power the pumps. Previously such operations used a hard-piped manifold that would run along the rear of the trucks, or trailers, on which the pumps are mounted so as to reduce the likelihood that the piping would be driven over.

However, such techniques often locate the gas line in the highest risk area on a pressure pumping location. Specifically, this location is where the high pressure water is pressurized up to 15,000 psi for injection as part of the completion operations. Additionally, such techniques provide for piping that cannot be easily moved, often requires multiple trucks to relocate, and lacks adaptability required for efficient use at different locations.

Furthermore, such hard-piped manifolds distribution pipes are heavy to transport, requiring multiple heavy duty trucks for transporting the hardware for a single site. Additionally, such systems can take a significant amount of time to set up, costing valuable time that could be otherwise used for pumping. Furthermore, this method also requires that a set section of pipe and flexible pipe fits each site. In order to ensure that suitable pipes and flexible pipe fits are available for a particular site, such techniques require multiple sections and sizes of extra pipe to be transported and stored on location, to allow for changing locations of one or more pumps as occasionally required at a site. Ultimately, this is not a flexible design.

According to various aspects of the present disclosure, as will be described in more detail below, a fluid distribution apparatus may include a trailer having a central platform and one or more sets of wheels. The central platform may include two or more hose reels mounted thereto, each of the hose reels including a reel that is rotatable about a rotation axis and a fluid distribution hose windable around the reel. The rotation axis of each of the hose reels may be generally parallel to a longitudinal axis of the central platform. The central platform may also include a manifold coupled with each of the hose reels and couplable with an external fluid source, such as a natural gas fuel source. The manifold may provide fluid from the external fluid source to each of the fluid distribution hoses of the respective hose reels. According to some aspects, one or more of the fluid distribution hoses may be coupled with an engine of a positive displacement pump. The positive displacement pump(s) may be coupled with a hydraulic fracturing fluid source and may pump the hydraulic fracturing fluid into a hydrocarbon producing well as part of the completion operations for the well. The engine(s) of the positive displacement pump(s) may be, for example, dual fuel engines capable of operating using a mixture of diesel fuel and natural gas.

Thus, the following description provides examples, and is not limiting of the scope, applicability, or configuration set forth in the claims. Changes may be made in the function and arrangement of elements discussed without departing from the spirit and scope of the disclosure. Various examples may omit, substitute, or add various procedures or components as appropriate. For instance, the techniques described may be performed in an order different from that described, and various steps may be added, omitted, or combined. Also, features described with respect to certain examples may be combined in other examples.

Referring first to FIGS. 1-9, a gas distribution trailer 100 according to various aspects is discussed. The trailer 100 may be used in hydrocarbon well drilling and completion operations, for example, to distribute fluid (gas or liquid), such as natural gas, from a central fluid storage unit to individual units in need of the fluid, such as pump engines that operate positive displacement pumps that pump hydraulic fracturing fluid into hydrocarbon producing wells, for example. The distribution trailer 100 may include a central platform 105 on top of which are positioned one or more circular hose reels 110a through 110-f. The central platform 105 has a length and a width, and in certain examples the length is greater than the width and a longitudinal axis extending along the length of the central platform. The distribution trailer further includes a manifold 115 which transports fluid from the central fluid storage unit to each individual circular hose reel 110. Each hose reel 110 includes a hose 120 which can be unwound from the hose reel and connected with a unit in need of fluid, such as an internal combustion engine that requires fuel for operation.

The central platform 105 of the distribution trailer 100 can be provided with wheels 125 such that the entire unit 100 is mobile. Any number of wheels 125 can be used and can be positioned in any of a variety of locations. The length and width of the central platform 105 is generally not limited. In some embodiments, the length and width of the trailer 100 is within the dimensions allowing the trailer 100 to be safely and legally transported on public roads. The dimensions of the trailer 100 can also be adjusted to accommodate the size of the hose reels 110. For example, when numerous hose reels 110 are used on the trailer 100, the length of the trailer 100 can be extended to accommodate the extra hose reels 110. Similarly, when the diameter of the hose reels 110 is increased, the width of the trailer 100 can be increased so that none of (or only a small portion of) each hose reel 110 extends over the edge of the trailer 100.

Any number of circular hose reels 110 can be positioned on and secured to the central platform 105. In some embodiments, the number of circular hose reels 110 is in the range of from 2 to 6. The circular hose reels 110 can be positioned perpendicular to the longitudinal axis of the central platform 105. In this configuration, pulling the hoses 120 off each hose reel 110 leads to the hoses 120 extending off of the lateral sides of the trailer 100. The diameter of each hose reel 110 is not limited, and may be adjusted to accommodate the length of the hose 120 associated with the hose reel. In some embodiments, all of the hose reels 110 on the trailer 100 are identical. In some embodiments, different size hose reels 110 are used on the same trailer 100, such as illustrated with hose reel 110-f, for example.

Each hose reel 110 includes a fluid passage the extends from an exterior position to an interior position of the hose reel 110. The exterior position is provided so that the hose reel 110 can be fluidly connected to the manifold 115 described in greater detail below. The interior position is provided so that the hose 120 can be fluidly connected to the hose reel 110. Fluid passing from the manifold 115 to the hose reel 110 travels through the fluid passage and into the hose 120.

As noted above, each hose reel 110 includes a hose 120, which may be made of a flexible material. The hose 120 wound on each hose reel 110 can be pulled out and connected with an individual unit in need of fluid, and can be wound back up on the reels 110 when not in use. In some embodiments, the length of the hose 120 is sufficiently long so as to reach a unit in need of fluid positioned a distance away from the distribution trailer 100. Any suitable hose length can be used. In some embodiments, the hose length is 150 feet. An electric motor can be used to assist with winding and unwinding the hoses 120 on the hose reels 110. The electric motors for the hose reels 110 may be powered by an electric generator 130 located on the central platform 105, in some examples. Additionally, or alternatively, mechanical handles may be used either as primary or secondary means for winding and unwinding the hose 120.

The type of hose 120 provided on each hose reel 110 is generally not limited and can be adjusted based on the specific application of the distribution trailer 100. For example, when the hose 120 is used to transport natural gas, a hose suitable for transporting natural gas is used. The material, thickness, and diameter of the hose 120 can be adjusted based on the fluid being transported through the hose 120 and other factors. The distal end of the hose 120 can include any of a variety of attachment mechanisms so that the hose can be attached to the unit in need of fluid. In some embodiments, the hose 120 includes a quick connect mechanism that allows for fast attachment and detachment of the hose to the unit in need of fluid. The proximal end can also include an attachment mechanism for attaching the hose 120 to the hose reel 110.

The distribution manifold 115 provided on the trailer can be positioned along the length of a lateral side of the central platform 105. The manifold 115 includes individual extensions 135 that are roughly aligned with each hose reel 110, according to certain examples. The extensions 135 may transport fluid from the central manifold 115 piping to each hose reel 110. Valves 140 can be provided at the juncture between the central manifold 115 piping and the extensions 135 so that extensions 135 can be turned off and on depending on whether the extension is connected with a hose reel 110, or depending upon a particular hose reel 110 is being used to deliver fluid through its associated hose 120.

The dimensions and materials of the distribution manifold 115 are generally not limited and can be adjusted based on the specific application of the trailer 100. For example, when the trailer 100 is being used to supply natural gas, the distribution manifold 115 can be made from a material suitable for transporting natural gas and having suitable dimensions for transporting natural gas, such as, for example, 3 inch stainless steel piping for the main manifold 115 pipe with 2 inch stainless steel piping used for the extensions 135. Of course, other suitable materials can be used based on the application and materials to be supplied, as will be readily recognized by one of skill in the art.

At one end, the distribution manifold 115 may be connected to the central fluid storage unit through a fluid connection 145 so that fluid can be transported from the central fluid storage unit to and through the manifold 115. At the other end, the distribution manifold 115 may include a blind 150 that may be removed and coupled to, for example, another gas distribution trailer 100. Fluid running through the manifold 115 will travel up to each hose reel 110 via the individual connections 135 between each hose reel 110 and the manifold 115. Once the fluid flows up to the hose reel 110, the fluid then travels into the hose 120 wound on each hose reel 110. In some examples, a vent 160, as may best be seen in FIG. 8, may be coupled with the manifold 115 at one or more locations, such as at each extension 135, and may connect to a vent stack and remote vent. In certain examples, one or more nitrogen tanks 165 may be coupled with the manifold 115, and may be used to purge the manifold 115 and/or one or more connections or hoses.

In a specific application, illustrated in FIG. 9, a system 200 may include a distribution trailer 100-a may be used to provide natural gas from a natural gas source 205 to a pumping system 300 that includes, in certain examples, duel fuel engines 305 powering frac'ing pumps 310 that may pump hydraulic fracturing fluid 315 to a hydrocarbon well 320. The natural gas may be provided from natural gas source 205 to the individual hose reels 210 via manifold 215 that may include extensions 235 and valves 240, similarly as discussed above. The natural gas is distributed to each of the hose reels 210 and moves through the corresponding hoses 220. Each hose 220 may be connected to an individual duel fuel engine 305 so that natural gas can be provided through the hose 220 to the engine 305. In the example of FIG. 9, a number of pressure gauges 255 may be present at various locations on the manifold 215 (also illustrated in the examples of FIGS. 1-8 as 155). Additionally, a vent 260 may be coupled with the manifold 115 at one or more locations (such as at each extension 235) and may connect to a vent stack and remote vent, similarly as discussed above.

The advantages of a gas distribution trailer such as described herein include portability and adaptability. In some examples, the trailer may be moved with a single truck, although it will be understood that other examples may be embodied on a skid that may also be transported. Certain examples include multiple large hose reels with 150 foot sections of flexible gas hose that can be pulled out to the length needed and reeled back in when a truck/pump needs to be pulled out. The trailer can be mobilized and moved at any time during the pressure pumping operation making a site adaptable solution. Furthermore, it may be operated by a single person and does not require any special equipment to move in some embodiments. An electric motor may be used to retract the hose on the reel with a mechanical handle backup, providing flexibility and ease of use. Each hose end may include a quick connect end to quickly hook up to a pump engine, for example. In some examples, embodiments provide relatively easy and quick setup, as a person may park the trailer outside of the pumping area in a “safe zone” and pull hoses to desired locations. The set-up may occur at any point in the operation, as the trailer merely needs to be parked and then hook up can commence. Unlike the previously used single rigid pipe set up described above, in which the piping runs the distance of the trucks (pressurized with natural gas), this trailer is adaptable to as many engines needed. Natural gas can be provided in whichever line or lines are desired, with no need to fill the entire manifold. Increasing its adaptability, this trailer can connect multiple gas distribution trailers in series to expand the number of reels and engines available for gas. Finally, the trailer is designed to have easy access to additional safety devices with a common vent line to vent stack on trailer and a remote vent.

The previous description of the disclosure is provided to enable a person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the spirit or scope of the disclosure. Throughout this disclosure the term “example” or “exemplary” indicates an example or instance and does not imply or require any preference for the noted example. Thus, the disclosure is not to be limited to the examples and designs described herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A mobile fluid distribution apparatus, comprising:

a trailer comprising a central platform coupled with a set of wheels, the central platform having a length greater than a width, and having a longitudinal axis extending along the length thereof;

two or more hose reels mounted to the central platform, each of the hose reels comprising a reel that is rotatable about a rotation axis and a fluid distribution hose windable around the reel, wherein the rotation axis of each of the hose reels is parallel to the longitudinal axis; and

a manifold coupled with each of the hose reels and couplable with an external fluid source, the manifold coupled with each of the hose reels to provide fluid from the external fluid source to each of the fluid distribution hoses of the respective hose reels.

2. The apparatus of claim 1, further comprising:

a common vent header coupled with the manifold.

3. The apparatus of claim 2, wherein the common vent header is coupled with the manifold at multiple locations, each location adjacent to a connection between the manifold and one of the hose reels.

4. The apparatus of claim 1, wherein each of the hose reels further comprise a winding mechanism configured to wind the fluid distribution hose on the hose reel.

5. The apparatus of claim 4, wherein the winding mechanism comprises one or more of an electric motor or a mechanical handle.

6. The apparatus of claim 5, further comprising an electric generator configured to provide electric power to one or more of the winding mechanisms.

7. The apparatus of claim 1, wherein each of the fluid distribution hoses is extendable off of the central platform in a direction perpendicular to a first longitudinal side of the central platform.

8. The apparatus of claim 7, wherein the manifold extends along a second longitudinal side of the central platform, the second longitudinal side on an opposite side of the hose reels from the first longitudinal side.

9. The apparatus of claim 1, wherein at least one of the hose reels has a different diameter than one or more other of the hose reels.

10. The apparatus of claim 1, wherein the manifold comprises two or more individual extensions aligned with each of the two or more hose reels and coupled with a fluid inlet of each respective hose reel.

11. The apparatus of claim 1, wherein the manifold comprises an intake valve located on a first end thereof and couplable with the external fluid source and a manifold expansion flange couplable with a second intake valve of a second mobile fluid distribution apparatus.

12. The apparatus of claim 1, wherein the fluid comprises natural gas and wherein each of the fluid distribution hoses provides natural gas to an engine of a pump used for hydraulic fracturing operations.

13. A fluid distribution system, comprising:

an external fluid source;

a fluid distribution trailer comprising: a central platform coupled with a set of wheels, the central platform having a length greater than a width, and having a longitudinal axis extending along the length thereof; two or more hose reels mounted to the central platform, each of the hose reels comprising a reel that is rotatable about a rotation axis and a fluid distribution hose windable around the reel, wherein the rotation axis of each of the hose reels is parallel to the longitudinal axis; and a manifold coupled with each of the hose reels and coupled with the external fluid source, the manifold coupled with each of the hose reels to provide fluid from the external fluid source to each of the fluid distribution hoses of the respective hose reels; and

one or more pump engines coupled with one or more of the fluid distribution hoses, the one or more pump engines providing power to an associated positive displacement pump used to pump hydraulic fracturing fluid for hydraulic fracturing operations.

14. The apparatus of claim 13, wherein the external fluid source comprises a natural gas fuel source.

15. The apparatus of claim 13, wherein each of the fluid distribution hoses is extendable off of the central platform in a direction perpendicular to a first longitudinal side of the central platform.

16. The apparatus of claim 15, wherein the manifold extends along a second longitudinal side of the central platform, the second longitudinal side on an opposite side of the hose reels from the first longitudinal side.

17. The apparatus of claim 13, wherein at least one of the hose reels has a different diameter than one or more other of the hose reels.

18. The apparatus of claim 13, wherein the manifold comprises two or more individual extensions aligned with each of the two or more hose reels and coupled with a fluid inlet of each respective hose reel.

19. The apparatus of claim 13, wherein the manifold comprises a manifold expansion flange coupled with a second fluid distribution trailer.

20. The apparatus of claim 13, wherein each of the positive displacement pumps is coupled with a source of hydraulic fracturing fluid and pumps the hydraulic fracturing fluid into a hydrocarbon producing well, and wherein the one or more pump engines is a dual fuel engine that operates using natural gas and diesel fuel.