Mobile Pump System
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 present disclosure relates to a mobile pump system and a method for performing a pressure pumping application including the mobile pump system.
2. Technical ConsiderationsPressure pumping includes a propagation of fractures through layers of rock using pressurized fluid and/or pumping cement into a wellbore to complete it.
In one non-limiting example of pressure pumping, to extract oil and/or gas trapped in formations beneath the Earth's surface, drilling of a wellbore is required, and the oil and/or gas may be recovered and extracted through the wellbore. Various pumps may be used during the drilling and oil and/or gas recovery process.
In some non-limiting oilfield applications, drilling may include forming horizontal laterals extending out from a vertical section of the wellbore. The formation defining the vertical or lateral section may be fractured in sections, such that a fracture stimulation treatment is completed in the first section before moving on to apply a fracture stimulation treatment on a second section. This may be performed using a plug-and-perf technique in which a perforating gun is used to initiate fractures in the formation in the section after a plug is positioned between the first section and the second section. The plug seals the first section of the lateral from the other sections. This plug-and-perf technique is repeated for each section of the lateral until all intended sections of the lateral are perforated and fracture stimulated.
The plug may be positioned at a predetermined location along the lateral by utilizing a pump system to pump a fluid into the wellbore, which exerts a pressure on the plug. The pressure on the plug moves the plug along the lateral to the desired position. Positioning the plug using the pump is considered an ancillary application, commonly referred to as “pumpdown”.
Existing pumps used in pressure pumping application, such as in ancillary pumpdown applications have numerous drawbacks. For example, existing pumps use an internal combustion engine driven by diesel fuel, which have high carbon footprints. In addition, these existing pumps are cumbersome and require considerable room at the well site. Further, these existing pumps do not allow for sufficiently precise control of flow rate, making it difficult to move the plug to the desired position. Existing pumps are expensive to acquire and maintain, and they create significant noise at a decibel level that is known to harm human hearing without adequate ear protection.
Further, existing pumping systems utilized in pressure pumping applications, including ancillary pressure pumping applications, are not capable of sufficiently low flow rates or precise control of the flow rate or pump pressure. The existing pump systems lack precise control and the ability to operate at lower flow rates because they utilize conventional transmissions that are incapable of smooth increase or decrease in pumping rates. This may be the result of hesitation and slugging common when primary gears disengage and engage the secondary shaft. As a result, existing pressure pumping systems do not effectively remedy screen outs occurring during hydraulic fracturing applications.
Further, higher rates may oftentimes be required for certain pumping applications. Many existing single pump systems are required to be located at a well site which take up considerable room, thereby affecting the standards of safety with increased personnel and more treating equipment like hoses and high pressure treating irons, affecting the cost of the well pad and causing large expenditures in construction of the well pad to accommodate the multiple pumping systems, and requiring increased amounts of diesel fuel to be trucked to location and dispersed among the pumps as they are engaged in high pressure and/or high rate operations.
Further, existing pumping systems utilized in pressure pumping applications are costly to build and to operate. Traditional diesel-powered pumps require regular repair and maintenance which can inflate operational costs. Diesel is a comparatively expensive fuel and is a cause of a variety of pollutants and greenhouse gases when burned when compared to an alternate fuel source like natural gas, and diesel engines also require certain maintenance that leads to significant waste streams and monetary expenditure being required.
Therefore, a pump suitable for pressure pumping applications that overcomes some or all of the disadvantages of existing pumps is desired.
SUMMARYThe present disclosure is directed to a mobile pump system including: at least one trailer movable by a vehicle; a plurality of pumps including a first pump and a second pump, where the first pump and the second pump are each mounted to the at least one trailer, where 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, 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 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, where the second set point is greater than or equal to the first set point.
The first pump may configured to pump fluid at a flow rate as low as 2.5 bpm and at a flow rate of up to 30 bpm, and the second pump may be configured to pump fluid a flow rate as low as 0.1 bpm. The first pump may include a multi-stage centrifugal injection pump. The first pump may include a pressure-balanced pump. The second pump may include a positive displacement pump. The positive displacement pump may be a reciprocating triplex or quintuplex pump. The control system may include 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. The electronic governor may be 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. The power source may be directly coupled to the first pump, where the direct coupling may include a non-variable, fixed ratio direct-coupled connection or a direct-coupled gear connection including a speed reducer. The second pump may be powered by an electric motor receiving power generated by the power source. The control system may be 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, where the first set point is at least 1.5 bpm. The mobile pump system may not be permanently installed at a site for performing a pressure pumping application. The power source may be operated using field gas. The first pump and/or the second pump may be configured to pump fluid at a pressure of 15,000 psi or greater. The mobile pump system may include 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, where the third pump is configured to pump fluid from the fluid storage tank to the first pump and/or the second pump. The pumping fluid may be 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 may be 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.
The present disclosure is also directed to a method for performing a pressure pumping application, including positioning a mobile pump system on a pump site. The mobile pump system includes: at least one trailer movable by a vehicle; a plurality of pumps including a first pump and a second pump, where the first pump and the second pump are each mounted to the at least one trailer, where 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, 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 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, where the second set point is greater than or equal to the first set point.
The method may include 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, where the first set point is at least 1.5 bpm. The method may include 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. The method may include positioning a plug in a lateral of a wellbore using fluid pumped into the wellbore via the mobile pump system. The method may include performing, using the mobile pump system, a toe prep application, a drill-out application, an industrial purging application, a pipeline pressure testing application, and/or a hydro-blasting application.
Further embodiments are set forth in the following numbered clauses:
Clause 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.
Clause 2: The mobile pump system of clause 1, wherein the first pump is configured to pump fluid at a flow rate as low as 2.5 or 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.
Clause 3: The mobile pump system of clause 1 or 2, where the first pump comprises a multi-stage centrifugal injection pump.
Clause 4: The mobile pump system of any of clauses 1-3, wherein the first pump comprises a pressure-balanced pump.
Clause 5: The mobile pump system of any of clauses 1-4, wherein the second pump comprises a positive displacement pump.
Clause 6: The mobile pump system of clause 5, wherein the positive displacement pump is a reciprocating triplex or quintuplex pump.
Clause 7: The mobile pump system of any of clauses 1-6, 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.
Clause 8: The mobile pump system of clause 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.
Clause 9: The mobile pump system of any of clauses 1-8, 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.
Clause 10: The mobile pump system of any of clauses 1-9, wherein the second pump is powered by an electric motor receiving power generated by the power source.
Clause 11: The mobile pump system of any of clauses 6-10, 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.
Clause 12: The mobile pump system of any of clauses 1-11, wherein the mobile pump system is not permanently installed at a site for performing a pressure pumping application.
Clause 13: The mobile pump system of any of clauses 1-12, wherein the power source is operated using field gas.
Clause 14: The mobile pump system of any of clauses 1-13, wherein the first pump and/or the second pump are configured to pump fluid at a pressure of 15,000 psi or greater.
Clause 15: The mobile pump system of any of clauses 1-14, 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.
Clause 16: The mobile pump system of any of clauses 1-15, 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.
Clause 17: A method for performing a pressure pumping application, comprising: positioning the mobile pump system of any of clauses 1-16 on a pump site.
Clause 18: The method of clause 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.
Clause 19: The method of clause 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.
Clause 20: The method of any of clauses 17-19, further comprising: positioning a plug in a lateral of a wellbore using fluid pumped into the wellbore via the mobile pump system.
Clause 21: The method of any of clauses 17-20, further comprising: performing, using the mobile pump system, a toe prep application, a drill-out application, an industrial purging application, a pipeline pressure testing application, and/or a hydro-blasting application.
Additional advantages and details are explained in greater detail below with reference to the exemplary embodiments that are illustrated in the accompanying schematic figures, in which:
For purposes of the description hereinafter, the terms “end,” “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments or aspects of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments or aspects disclosed herein are not to be considered as limiting.
No aspect, component, element, structure, act, step, function, instruction, and/or the like used herein should be construed as critical or essential unless explicitly described as such. Also, as used herein, the articles “a” and “an” are intended to include one or more items and may be used interchangeably with “one or more” and “at least one.”
The present disclosure is directed to a mobile pump system that includes: a trailer movable by a vehicle; and a pump mounted to the trailer, the pump configured to pump a fluid, wherein the pump comprises an electrically-driven motor mounted to the trailer or is turbine powered by a turbine mounted to the trailer. The mobile pump system described herein may be suitable for pressure pumping applications.
The present disclosure is also directed to 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.
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With continued reference to
The lateral 14 may include a plurality of regions, which are of a predetermined length. Hydraulic fracture stimulation treatment may be performed in the lateral 14 individually at each region. Hydraulic fracture stimulation treatment includes pumping a fracturing fluid into the formation. The lateral 14 of the schematic in
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With continued reference to
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In
The second plug 40 may be positioned using the mobile pump system 44 of the present disclosure. The mobile pump system 44 may be used to position the second plug 40 as merely one non-limiting example of how the mobile pump system 44 may be used in a pressure pumping application. However, it will be appreciated that the mobile pump system 44 may be used to complete other pressure pumping applications using the components of the mobile pump system 44 described hereinafter.
The mobile pump system 44 may include a trailer 46 movable by a vehicle (e.g., a cab having a fifth wheel). The trailer 46 may be movable by a vehicle, such as a cab, to and from the production site 10. In this way, the mobile pump system 44 may be conveniently moved from location to location, such as to and from the production site 10, and the mobile pump system 44 does not need to be permanently installed at the production site 10. The trailer 46 may be separable/detachable from the vehicle such that the trailer 46 may be left at the production site 10 and the vehicle driven away, or the trailer 46 may be integrated with the vehicle, such that the vehicle remains at the production site 10 while the mobile pump system 44 is in use and drives away after use of the mobile pump system 44 is completed.
With continued reference to
The at least one pump 48 may be configured to pump the positioning fluid 42, or any other fluid, at a flow rate of up to 30 barrels per minute (bpm), such as up to 60 bpm, up to 80 bpm, up to 100 bpm, up to 120 bpm, up to 140 bpm or higher. A barrel is defined as 42 US gallons, which is approximately 159 Liters. The at least one pump 48 may be configured to pump the positioning fluid 42 at far lower flow rates, and may pump the positioning fluid 42 at a flow rate as low as 0.1 bpm (when the pump is not turned off such that it's flow rate would be 0 bpm). The at least one pump 48 may be controlled such that its flow rate may be controlled within 0.1 bpm, resulting in a flow rate within 0.1 bpm compared to a predetermined flow rate. The pump may be configured to adjust the flow rate by 0.1 bpm (e.g., adjust the flow rate of the at least one pump 48 from 60.0 bpm to 59.9 bpm or from 0.2 bpm to 0.1 bpm). Existing pressure pumping systems, including ancillary pressure pumping applications, are not capable of such low flow rates or such precise control of the flow rate. The existing pump systems lack precise control and the ability to operate at lower flow rates because they utilize conventional transmissions that are incapable of smooth increase or decrease in pumping rates. This may be the result of hesitation and slugging common when primary gears disengage and engage the secondary shaft.
The ability to pump at lower rates and to more precisely control the flow rate of the at least one pump 48 may be especially useful in post-occurrence remedying of “screen outs,” which are common in hydraulic fracturing applications. A screen out occurs when proppant and fluid (of the positioning fluid 42, for example) can no longer be injected into the formation. This may be due to resistant stresses of the formation becoming too excessive or surface-originated reasons resulting in loss of viscosity to carry proppant so that it falls out of suspension and plugs perforations in the wellbore 12. In this way, the wellbore 12 becomes “packed” with proppant, which does not allow any further operations to continue due to high pressures that cannot be overcome from these blockages.
In response to screen outs, the wellbore 12 may be opened at the surface 11 to relieve pressure and to carry at least some of the proppant out of the wellbore 12 and create a pathway to continue fluid injection to clear the wellbore 12 and allow operations to continue, which is a dangerous operation. An attempt to continue pumping operations at low rates to avoid reaching maximum pressure so that the proppant that is packed is forced through perforations and into the wellbore 12 may be attempted. However, due to the limitations of existing pumps with conventional engines and transmissions, the pump cannot pump at low enough rates to avoid again reaching maximum pressure. As a result, existing systems are often required to switch to a coiled tubing procedure to wash the proppant out and carry it back to the surface so that the wellbore 12 is finally clear. The coiled tubing procedure results in shutdown of operations for 3-4 days and is additionally expensive to complete.
In contrast to existing systems, the mobile pump system 44 is able to overcome these screen outs successfully without reverting to the coiled tubing procedure because the electric motor and/or the turbine and/or the natural gas fired reciprocating engine 50 of the at least one pump 48 allows the at least one pump 48 to inject fluid for displacement at lower rates (as low as 0.1 bpm) over the course of hours or days without the risks posed by existing systems.
The ability to pump fluids at lower rates and to more precisely control the flow rate of the at least one pump 48 may be especially useful in prevention or mitigation of the adiabatic effect which can cause wireline cable melting and/or failure during pumpdown operations, which are common in hydraulic fracturing applications. On pumpdowns and related jobs involving wireline operations with pump assist, the wellhead is equipped with a lubricator and flow tubes to enable operations in a wellbore that can have pressure of several thousand pounds or more of pressure. The process of bringing the lubricator and the wellbore to the same pressure is known as “equalization.” When the air in the lubricator compresses faster than it can be evacuated, the adiabatic compression can cause the temperature to rise to as much as 1,200° F. (˜650° C.). At high temperatures, the insulating material of the cable would melt and the metallurgy of the steel in the cable would change, causing the actual wire in the wireline to become brittle and break, even to the point of severing the wireline within the lubricator. A common name for this condition is “wireline burn up” though other colloquialisms and phrases (such as “E-line burn”) describe the same condition.
In practice, to avoid wireline burn-up, the lubricator may first be filled with fluid prior to equalizing; this practice can mitigate much of the air and therefore most of the energy to cause damage. In order to fill the lubricator with fluid without inducing wireline burn-up, the fluid must be introduced at very low rates so that the air can be evacuated at an equivalent rate so as not to introduce temperature increases caused by compressing air rapidly. However, due to the limitations of existing pump systems with conventional engines and transmissions, the pump cannot pump at low enough rates to completely avoid against reaching damaging high temperatures. In contrast, the at least one pump 48 would be able to overcome this situation successfully because the electric motor and/or the turbine and/or the natural gas fired reciprocating engine 50 of the at least one pump 48 allows the at least one pump 48 to inject fluid for displacement of the air in the lubricator at lower rates (as low as approximately 0.1 bpm) without the risks posed by existing systems.
The at least one pump 48 may be configured to pump fluid at a pressure of up to 20,000 psi, such as up to 15,000 psi, up to 12,000 psi, up to 10,000 psi, up to 8,000 psi, or up to 6,000 psi, although higher pressures are also contemplated.
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The mobile pump system 44 described herein may be used for any pressure pumping in which its characteristics are suitable and is not limited to the above-described application. For example, the mobile pump system 44 may be used in hydraulic fracturing applications. Hydraulic fracturing applications include any application associated with hydraulic fracturing performed at a production site. Hydraulic fracturing refers to fluid injected down the wellbore through perforations exceeding the minimum fracture pressure needed to fracture the rock in the formation. An example of a hydraulic fracturing application includes ancillary applications (“pumpdown”), such as positioning a plug (previously described), drillout applications, injecting acid into the formation, pressure testing casing, injecting diverter materials, “toe preps” involving initiating the first fracture network in a well, and the like. Drillout applications may include applications performed after the drilling and fracturing process has concluded and the well is being prepared to deliver hydrocarbon production. As one example, a drillout application may include milling or drilling out plugs previously positioned in the laterals and removing debris from the milled plugs by pumping the debris from the plug location to the surface.
The mobile pump system 44 allows for the reduction of capital costs compared to existing pump systems as the mobile pump system 44 requires less capital costs to build and operate. The mobile pump system 44 also significantly reduces repair and maintenance costs compared to existing systems. The use of the electric motor and/or turbine and/or natural gas fired reciprocating engine 50 to drive the at least one pump 48 helps to reduce repair and maintenance costs. The electric motor and/or turbine and/or natural gas fired reciprocating engine 50 has a higher run time before requiring repairs compared to conventional internal combustion diesel engines (motors) used in existing pumps, which are diesel driven, for example. Keeping the electric motor and/or turbine and/or natural gas fired reciprocating engine 50 cool and lubricated allows the electric motor and/or turbine and/or natural gas fired reciprocating engine 50 to have a longer running life compared to the motors used in existing systems. The electric motor and/or turbine and/or natural gas fired reciprocating engine 50 also run more efficiently compared to the motors used in existing systems, such as in terms of emissions and consumption of fuel.
The mobile pump system 44 using the electric motor and/or turbine and/or natural gas fired reciprocating engine 50 to drive the at least one pump 48 also requires significantly less fuel, monetary expenditure to maintain, and results in less environmental waste from maintenance, compared to existing systems. The electric motor and/or turbine and/or natural gas fired reciprocating engine 50 may utilize natural gas-powered electric generation, such as the field gas available at a production site. Thus, sulfur and other pollutants that arise from diesel combustion in conventional internal combustion motors are not present in the combustion of natural gas powered electric generation. The inclusion of the electric motor and/or the turbine and/or the natural gas fired reciprocating engine 50 in the mobile pump system 44 also reduces the noise associated with the mobile pump system 44 as pumps used in existing systems provide significant noise pollution and make it difficult to operate such pumps in residential areas (e.g., near housing plans, schools, hospitals, and the like).
The mobile pump system 44 includes a more compact design of the pumps 48 compared with existing systems. Multiple pumps 48 may be included on the trailer 46. The more compact system contributes to a safer production site 10 as there are less components at the production site 10 to cause a navigational and/or tripping hazard. This compact design also allows for the mobile pump system 44 to be set-up faster, resulting in less wasted time and faster time to production. Moreover, the mobile pump system 44 may include multiple of at least one component included in the system, such as multiple pumps 48, multiple electric motors and/or turbines and/or natural gas fired reciprocating engines 50, multiple controllers 80, and the like. The redundancy associated with certain of the components mounted on the trailer 46 of the mobile pump system 44 allows the system to avoid stopping operation of the pressure pumping application should one of the redundant components fail.
Referring to
The production site 10 may include at least one fracturing trailer 58A-58F, each including at least one fracturing pump 60A-60F. The production site 10 may further include sand and fracturing fluid storage tanks 62, which include sand and fracturing fluid used to keep fractures in the formation open. The production site 10 may further include a water tank 64 for pumping water into the first wellbore 12A. The water tank 64 may be in addition to or the same as the fluid tank 54 containing the positioning fluid 42. The production site 10 may further include a chemical storage tank 66, which may store any useful chemical, such as a friction reducer (e.g., polyacrylamide or a guar-based chemical). The fracturing pumps 60A-60F may be in fluid communication with at least one of the sand and fracturing fluid storage tanks 62, the water tank 64, and the chemical storage tank 66 to pump the various materials and/or fluids contained therein into the first wellbore 12A via piping 70. The piping 70 may include an isolation valve 72 for isolating the fracturing pumps 60A-60F from the first wellbore 12A when the fracturing pumps 60A-60F are not pumping fluid/material into the first wellbore 12A.
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An exemplary graphical user interface (GUI) displayed on the controller 80 is shown in
Beyond providing the capability to adjust certain parameters of the system, the GUI may display on the controller various diagnostic and monitoring information. As non-limiting examples, the GUI may display electric motor and/or the turbine and/or the natural gas fired reciprocating engine temperature, fluid levels, and pump revolutions per minute.
Referring to
The mobile pump system 82 may include an electrical transformer 88 mounted on the trailer 84. The electrical transformer 88 may increase or decrease a voltage from an external power source for use by one of the components of the mobile pump system 82. This may allow components of the mobile pump system 82 to be powered by an external power source not included on the trailer 84 by electrically connecting the external power source to the transformer 88, which may be electrically connected to the other components.
The mobile pump system 82 may include the variable frequency drive 90 mounted on the trailer 84. The variable frequency drive 90 may include an electro-mechanical drive system to control motor speed and/or torque of the electric motor 94 by varying motor input frequency and/or voltage.
The mobile pump system 82 may include the heat exchanger 92 mounted on the trailer 84 to regulate temperature of at least one of the other components (e.g., the electric motor 94 and/or the pump 96), such that the component can operate more efficiently. The heat exchanger 92 may function as a cooler to prevent a component of the mobile pump system 82 from overheating.
The mobile pump system 82 may include the electric motor 94 mounted on the trailer 84, the electric motor 94 as previously described herein. The mobile pump system 82 may also include the pump 96a, 96b (a single or multiple pumps may be included) mounted on the trailer 84. The pump 96a, 96b may include the features previously described herein in connection with at least one pump 48. The pump 96a, 96b may be driven by the electric motor 94.
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The mobile pump system 102 may include an inlet filter silencer 106 mounted on the trailer 84 to reduce noise emitted by any of the components included in the mobile pump system 102.
The mobile pump system 102 may include a turbine and/or a natural gas fired reciprocating engine 108a, 108b (a single or multiple turbines and/or natural gas fired reciprocating engines may be included) mounted on the trailer 84 and connected to the pump 96a, 96b. The turbine and/or natural gas fired reciprocating engine 108a, 108b may be enclosed in a housing. The turbine and/or natural gas fired reciprocating engine 108a, 108b may be an on-board (on the trailer 84) turbine and/or natural gas fired reciprocating engine to generate power on the trailer 84 for driving the pumps 96a, 96b. The turbine and/or natural gas fired reciprocating engine 108a, 108b may be directly coupled to the pump 96a, 96b via a gearbox 110a, 110b (a speed reduction mechanism may be included), which may include gear reduction components. The turbine and/or natural gas fired reciprocating engine 108a, 108b may be powered by using field gas (e.g., natural gas) e.g., introduced to the turbine to spin the turbine blades to create power to rotate the pump 96a, 96b. The power generated by the turbine and/or the natural gas fired reciprocating engine 108a, 108b may drive the pump 96a, 96b. The turbine and/or natural gas fired reciprocating engine 108a, 108b may be included in the mobile pump system 102 in addition to or in lieu of the electric motor 94a, 94b shown in the mobile pump system 82 shown in
Referring to
The fuel tank 114 may be used as a backup fuel supply in the event of a fuel supply interruption. A fuel supply interruption may include the interruption of field gas (e.g., natural gas supplied directly from the production site at which the mobile pump system 112 is located) to the mobile pump system 112. Inclusion of the fuel tank 114 on the trailer 84 allows the mobile pump system 112 to continue operation even in the event of such a fuel supply interruption, without the deployment of an emergency backup power supply to the production site.
The mobile pump system 112 may include a conditioning system 116 configured to condition the gas from the fuel tank 114 or the field gas supplied to the mobile pump system 112. The conditioning system 116 may include a gas heater to drop out solids and/or water from the gas and return it to the supply line. The conditioning system 116 may include at least one filter to filter out impurities in the fuel that could cause the system to malfunction.
Referring to
The plurality of pumps 206a, 206b, 208, 218 may include at least one first pump 206a, 206b. In the non-limiting example of the mobile pump system 200 shown in
The inclusion of the first pump 206a as a multi-stage centrifugal injection pump in combination with the positive displacement second pump 208 (described hereinafter) allows for costs of including a multiple high-cost pressure displacement pumps capable of operating at relatively higher flow rates (those flow rates associated with the first pump 206a ) to be avoided.
The plurality of pumps 206a, 206b, 208, 218 may include at least one second pump 208. In the non-limiting example of the mobile pump system 200 shown in
The first pump 206a may have a higher flow rate capability and/or a higher pumping pressure capability compared to the second pump 208. The second pump 208 may have a lower flow rate capability and/or a lower pumping pressure capability compared to the first pump 206a . The flow rate capability and/or the pumping pressure capability of the first pump 206a and the second pump 208 may include an overlap. The first set point and/or the second set point (described hereinafter) may fall within the overlap.
With continued reference to
With continued reference to
With continued reference to
The mobile pump system 200 may include a third pump 218 mounted on the trailer 202. The third pump 218 may be in fluid communication with at least one of the fluid storage tank, the first pump 206a, 206b, and the second pump 208 by the conduit 214. The third pump 218 may be configured to pump fluid from the fluid storage tank to at least one of the first pump 206a, 206b and the second pump 208. The third pump 218 may be a volute-type centrifugal pump and may pump fluid from the at least one of the fluid storage tank to the first pump 206a, 206b and/or the second pump 208 by the conduit 214 at a flow rate of from 0-3.5 bpm, such as 0-2.5 bpm and at a pressure of up to 15,000 psi.
With continued reference to
The control system 216 may include an electronic governor configured to control at least one of the rotational speed of the turbine and/or the natural gas fired reciprocating engine 204, the flow rate of the first pump 206a, 206b and/or the second pump 208, and the pumping pressure of the first pump 206a, 206b and/or the second pump 208. The control system 216 may communicate the instructions for the components of the mobile pump system 200 to the electronic governor to cause the electronic governor to communicate with the components to cause the instructions to be effected by the components. The control system 216 enables the mobile pump system 200 to control small incremental adjustments in the rotational speed of the turbine and/or the natural gas fired reciprocating engine 204, the flow rate of the first pump 206a, 206b and/or the second pump 208, and the pumping pressure of the first pump 206a, 206b and/or the second pump 208 without transmission or gear-based controls, which lack the capability for the highly precise controls of the mobile pump system 200.
The control system 216 may receive set point data from a user that specifies a desired a rotational speed of the turbine and/or the natural gas fired reciprocating engine 204, a flow rate of the first pump 206a, 206b and/or the second pump 208, and/or a pumping pressure of the first pump 206a, 206b and/or the second pump 208, such as by the user entering the set point data into a graphical user interface. Based on the user specifying a desired rotational speed of the turbine and/or the natural gas fired reciprocating engine 204, the control system 216 may automatically generate instructions (based on the advanced control algorithm, for example) to cause the first pump 206a, 206b and/or the second pump 208 to operate at a flow rate and/or a pumping pressure, such that the desired rotational speed may be changed or maintained. Based on the user specifying a flow rate of the first pump 206a, 206b and/or the second pump 208, the control system 216 may automatically generate instructions (based on the advanced control algorithm, for example) to cause the first pump 206a, 206b and/or the second pump 208 to operate at a pumping pressure and/or the turbine and/or the natural gas fired reciprocating engine 204 to operate a rotational speed, such that the desired flow rate may be maintained. Based on the user specifying a pumping pressure of the first pump 206a, 206b and/or the second pump 208, the control system 216 may automatically generate instructions (based on the advanced control algorithm, for example) to cause the first pump 206a, 206b and/or the second pump 208 to operate at a flow rate and/or the turbine and/or the natural gas fired reciprocating engine 204 to operate a rotational speed, such that the desired pumping pressure may be maintained. Therefore, a deviation of the actual data value from the set point data value may cause the control system 216 to generate instructions to the relevant components to cause the components of the mobile pump system 200 to automatically adjust to return to the set point value.
The control system 216 may be configured to communicate (e.g., via the electronic governor) with the turbine and/or the natural gas fired reciprocating engine 204 to control the rotational speed of the turbine and/or the natural gas fired reciprocating engine 204. The control system 216 may adjust the rotational speed of the turbine and/or the natural gas fired reciprocating engine 204 by an incremental amount as low as the rpm required to change the flow rate by 0.1 bpm.
The control system 216 may be configured to communicate (e.g., via the electronic governor) with the first pump 206a, 206b and/or the second pump 208 to control the flow rate thereof. The control system 216 may adjust the flow rate of the first pump 206a, 206b and/or the second pump 208 by an incremental value as low as 0.1 bpm. In some non-limiting examples, the control system 216 may automatically adjust the flow rate of the first pump 206a, 206b and/or the second pump 208 to reach or maintain a pressure pumping set point value specified by the user for the first pump 206a, 206b and/or the second pump 208.
The control system 216 may be configured to communicate (e.g., via the electronic governor) with the first pump 206a, 206b and/or the second pump 208 to control the pumping pressure thereof. In some non-limiting examples, the control system 216 may automatically adjust the pumping pressure of the first pump 206a, 206b and/or the second pump 208 to reach or maintain a flow rate set point value specified by the user for the first pump 206a, 206b and/or the second pump 208.
With continued reference to
In one non-limiting illustrative example, the mobile pump system 200 may initially be deactivated, having a flow rate associated therewith of 0 bpm. The mobile pump system 200 may be activated to begin pumping the pumping fluid, and the control system 216 may activate the second pump 208 to begin the pumping application. The second pump 208 may pump the pumping fluid with the first pump 206a, 206b deactivated at lower flow rates (below the first set point and/or below the minimum flow rate pumping capability of the first pump 206a, 206b). Thus, the third pump 218 may flow the pumping fluid from the fluid storage tank to the second pump 208 when the flow rate of the mobile pump system 200 is below the first set point, such that the second pump 208 moves the pumping fluid to the outlet. Upon the flow rate of the mobile pump system 200 reaching the first set point, the control system 216 may activate the first pump 206a, 206b to cause the first pump 206a, 206b to pump pumping fluid. Thus, the third pump 218 may flow the pumping fluid from the fluid storage tank to the first pump 206a, 206b when the flow rate of the mobile pump system 200 reaches the first set point, such that the first pump 206a, 206b moves the pumping fluid to the outlet. At a second set point equal to or higher than the first set point, the control system 216 may deactivate the second pump 208 so that only the first pump 206a, 206b (of the first 206a, 206b and second pumps 208) is moving pumping fluid to the outlet. The first pump 206a, 206b may pump the pumping fluid at a flow rate above the capabilities of the second pump 208. In some non-limiting examples, the first set point is equal to the second set point, such that as the control system 216 activates the first pump 206a, 206b, the second pump 208 is deactivated (at the same set point). In some non-limiting examples, the second set point is higher than the first set point such as between the first set point and the second set point, the first pump 206a, 206b and the second pump 208 work in tandem to flow pumping fluid to the outlet.
With continued reference to
As illustrated by the above-described operation of the control system 216 controlling activation and deactivation of the first pump 206a, 206b and the second pump 208, the mobile pump system 200 has been designed to handle ancillary pressure pumping applications associated with hydraulic fracturing, which often require the full range of low rate/high pressure pumping applications to high rate/high pressure pumping applications. The combination of the first pump 206a, 206b and the second pump 208 on the mobile pump system 200 enables these pumping parameters to be achieved using a mobile system with lower capital costs. Further, the above-described activation and deactivation of the first pump 206a, 208 and the second pump 208 (e.g., in the operating order described) allows for the second pump 208 capable of operating at lower flow rates to hand-off the pumping application to the first pump 206a, 206b, which is capable of operating at higher flow rates.
The utilization of the first pump 206a, 206b in the mobile pump system 200, which may be a multi-stage centrifugal injection pump, at pump rates above 1.5 bpm, such as above 2.5 bpm, above 3.5 bpm, or above 5 bpm allows for fracture propagation to occur more efficiently compared to a pumping system only including a positive displacement pump. The multi-stage centrifugal injection pump allows for an almost instantaneous response to formation breakdown and is capable of increasing flow rate relatively more seamlessly to achieve a target pressure. Thus the combination of the first pump 206a, 206b with the second pump 208 of a different style on the trailer 202 allow for the pump more suitable for the particular pumping application (or stage thereof) to be seamlessly used on the mobile pumping system 200.
The mobile pump system 200 may include a fuel buffering system, which may be positioned to remove undesired liquids, solids, and other debris from the chamber of the turbine 204 and/or the natural gas fired reciprocating engine and/or to prevent such products from entering the chamber of the turbine and/or the natural gas fired reciprocating engine 204.
The turbine and/or natural gas fired reciprocating engine 204 may generate excess power, in excess of the power needed to power the mobile pump system 200, such that the excess power may be transferred to other on-site locations to power other on-site components. For example, the excess power may be directed to other on-site needs, such as wireline needs, water transfer needs, and the like. The turbine 204 may include a shaft on a side opposing the side of the mobile pump system 200 which may rotate a standard electric motor and/or generator and send the excess power (at a specified wattage) through a cable to the other on-site components to provide the necessary power requirement.
The mobile pump system 200, may be positioned on a pump site to perform a pressure pumping application thereon. The pressure pumping application may be an oil/gas-field or non-oil/gas-field-related application.
The mobile pump system 200 positioned on a pump site may be used to perform the previously-described “plug-and-perf” method in which a plug is positioned in a lateral of a wellbore using the fluid pumped into the wellbore by the mobile pump system 200.
The mobile pump system 200 positioned on a pump site may be used to perform a toe prep application. Toe prep applications prepare the well for the commencement of fracture stimulation operations. Toe preps involve establishing an initial pathway for fracture propagation into the reservoir from the well, thereby allowing fluid communication from inside the wellbore into the target formation. Toe preps may involve shifting casing sleeves through building pressure using fluid pumped by the mobile pump system 200 to provide the pathway for fluid to exit the casing into the formation. Toe preps may also involve tubing-conveyed perforating (TCP) and other wireline conveyed perforating, for example, in conjunction with the fluid pumped by the mobile pump system 200. Injection tests, like Diagnostic Fracture Injection Tests (DFIT), are commonly performed at the beginning of fracture stimulation operations and can be designed for low-rate/high pressure and/or high-rate/high pressure through the range of capabilities of the mobile pump system 200.
The mobile pump system 200 may be positioned at an agricultural site to move water or other fluid for an agricultural application. The mobile pump system 200 may be positioned at a mining site to move water or other fluid for a mining application, such as dewatering and or supplying water in coal and/or precious metal mining operations.
The mobile pump system 200 positioned on a pump site may be used to perform a drill-out application. Drill-out applications are performed after a well is fracture stimulated. During multi-stage fracture stimulation operations, plugs are placed in the lateral for zonal isolation prior to the performance of additional fracture stimulation stages. Typically plugs are spaced 150 ft to 300 ft apart in a wellbore but are not limited to those distances. At a time after fracture stimulations have been completed, these plugs are drilled out. A bit or mill is commonly placed at the end of a tubing string or coiled tubing, for instance, and is rotated to drill up each plug in succession. During drill-out operations, fluid may be circulated to keep the wellbore clean and to carry cuttings and debris out of the wellbore. This fluid is circulated by the mobile pump system 200 at potentially very low rates, such as 1-2 bpm (or lower), and higher rates, such as 8-9 bpm (or higher), depending on tubing and casing sizes, for instance, or condition of the well as regards sand from fracture stimulation operations and debris.
The mobile pump system 200 positioned on a pump site may be used to perform an industrial purging application. In industrial purging, piping associated with plant or factory operations, for instance, may require treatments that can include flushing debris, cleansing the system, or clearing blockages utilizing a fluid pumped by the mobile pump system 200.
The mobile pump system 200 positioned on a pump site may be used to perform a pipeline pressure testing application. Before pipelines are placed into service, pipeline pressure testing operations are utilized to assure that the system safely meets the maximum allowable operating pressures (MAOP). Additionally, pipelines are tested at regular intervals to assure safe operations with regard to pressure. Fluid is pumped into the pipeline(s) by the mobile pump system 200 and held at a designated pressure for a determined period of time. The mobile pump system's 200 precise controls can achieve designed pressures more accurately than conventional pumps, as in those involving diesel engines and transmissions.
The mobile pump system 200 positioned on a pump site may be used to perform a hydro-blasting application. Whereas sand blasting and dry blasting introduces particulate matter into the air, hydro-blasting utilizes no abrasives but utilizes fluid pressure (as in pressure washing) instead. Fluid pumped at a variety of pressures by the mobile pump system 200 with its precise controls can be utilized in a variety of applications, such as stripping old paint from metal surfaces, for example.
The mobile pump system 200 may perform a pressure pumping application by activating the second pump 208, with the first pump 206a, 206b deactivated, until a flow rate effected by the mobile pump system 200 is at least 1.5 bpm; and activating the first pump 206a, 206b, while the second pump 208 is still activated, once the flow rate effected by the mobile pump system 200 is at a first set point, the first set point being at least 1.5 bpm. Performing the pressure pumping application may further include deactivating the second pump 208, while the first pump 206a, 206b is still activated, once the flow rate effected by the mobile pump system 200 is at a second set point, the second set point being equal to or higher than the first set point.
Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.
Claims
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.
Type: Application
Filed: Oct 30, 2020
Publication Date: May 6, 2021
Inventors: Matthew Curry (McMurray, PA), Christopher Combs (Spring, TX), Neal Jensen (Henderson, NV)
Application Number: 17/084,899