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DESCRIPTION OF HYDRAULIC FRACTURING (FRACKING)
The operation entails using special pump/compressor pipes to pump highly viscous fluid (gel) based on water or hydrocarbons (petroleum, diesel fuel) into the well. The pressure created by the fluid fractures the formation along minimum stress planes of overburden pressure. As a result, a fracture forms in the formation. After fracking the fracture keeps growing as more fluid is pumped into the well.
When the fracture grows to a particular size, propping agent (proppant) is fed into the fracking fluid (artificial bauxite sand with spherical particles). The fluid takes the proppant to the fracture. The proppant must hold the fracture open when the pumping stops and the overpressure is withdrawn. At the final stage the gel pushes the proppant, which remains in the well after filling the fracture, into the formation.
In this way, by creating a proppant-filled fracture, formation volume drained by the well is expanded, previously untapped deposits are connected, and a high-throughput channel is formed to deliver oil into the well. This allows to increase the flow rate of the well several-fold (average increase for oil is 3-fold), increase the recovery ratio of the formation thus turning a part of non-commercial OIP into commercial oil reserves.
HYDRAULIC FRACTURING
RUSSIAN HYDRAULIC FRACTURING SPREAD
FOR OIL AND GAS FORMATIONS
HYDROFRACKING SPREAD LAYOUT DIAGRAM
1 – SKU-10; 2 – UN-2250; 3 – US-10; 4 – BM-105; 5 – MM-105; 6 – gel tank; 7 – proppant bunker.
HYDRAULIC FRACTURING SPREAD
AUTOMATED CONTROL AND MONITORING SYSTEM The spread facilitates automated (computerized) control of the hydrofracturing
process under oversight of the operations manager, the engineer, and the operator of the UN-2250 pumping unit, who are present at the SKU-10 monitoring and control station. It also enables visual monitoring of fracking parameters on three monitors and the main control panel of the SKU-10station, as well as on the US-10 blender.
Hydrofracking process parameters can be adjusted manually throughout the process; it is also possible to switch to manual control completely.
Components of hydrofracturing process control and monitoring (incl. visual) of fracking parameters are combined into the SAUK automated control and monitoring system, including:• System software• 2 industrial computers of the SKU-10 station • Three monitors of the SKU-10 station • Common control panel for pumping units in the SKU-10 station• Printer of the SKU-10 station• 1 industrial computer of the US-10 blender• Coupling hardware unit of the US-10 blender• Control and monitoring panel with a monitor and manual controls of the US-10
blender
SKU-10 MONITORING AND CONTROL STATION
SKU-10 MONITORING AND CONTROL STATION
The SKU-10 monitoring and control station automatically controls the UN-2250 (UN) pumping units and the US-10 blender as part of hydraulic fracturing of oil and gas formations. It maintains, as specified by industrial computer software or the operator, set points for working fluid and dry and liquid chemicals, and proppant concentration. It also monitors and logs parameters (direct and calculated), archives behavior and operating parameters of the spread, and logs behavior and operating parameters on paper media. Climatic category “U1” (temperate climate, outdoors) GOST 15150-69.
SKU-10 MONITORING AND CONTROL STATION
TECHNICAL DETAILS
No. Parameters Values1. Special van truck (on MAZ-5336A5-320 chassis)
1.1 Fully loaded mass (operating weight), not more than 120001.2 Number of compartments in the van 21.3 Number of workplaces 41.4 Number of seats for customer representatives (supervisors) 31.5 Main power supply from external 220V grid or own generator 1.6 Supplementary power supply 24VDC from truck battery 1.7 Equipment of the van
1.7.1 Diesel generator (220V, 9000W), quantity: 1 1.7.2 Air conditioner (220V, 2000W), quantity 11.7.3 Autonomous diesel air heater (24V), quantity 21.7.4 Electric heater, wall-mounted (220V, 1500W), quantity 21.7.5 Cabinet with fume hood for laboratory tests, quantity 11.7.6 Cabinet for computer hardware units , quantity 1
2 Special electrical equipment of the SKU2.1 Common control panel of the UN, quantity 12.2 Industrial computer, quantity 22.3 Monitors, quantity 32.4 Printer, quantity 12.5 50m cable reels, quantity 102.6 Stationary/remote projectors, quantity 4/2
TECHNICAL DETAILS
No. Parameters Values1. Special van truck (on MAZ-5336A5-320 chassis)
1.1 Fully loaded mass (operating weight), not more than 12000 kg1.2 Number of compartments in the van 21.3 Number of workplaces 41.4 Number of seats for customer representatives (supervisors) 31.5 Main power supply from external 220V grid or own generator 1.6 Supplementary power supply 24VDC from truck battery 1.7 Equipment of the van
1.7.1 Diesel generator (220V, 9000W), quantity: 1 1.7.2 Air conditioner (220V, 2000W), quantity 11.7.3 Autonomous diesel air heating (24V), quantity 21.7.4 Electric heater, wall-mounted (220V, 1500W), quantity 21.7.5 Cabinet with fume hood for laboratory tests, quantity 11.7.6 Cabinet for computer hardware units , quantity 1
2 Special electrical equipment of the SKU2.1 Common control panel of the UN, quantity 12.2 Industrial computer, quantity 22.3 Monitors, quantity 32.4 Printer, quantity 12.5 50m cable reels, quantity 102.6 Stationary/remote projectors, quantity 4/2
COMPONENTS AND EQUIPMENT OF SKU-10Cabinet withfume hood
Rack with computingequipment
Common control panelof the UN
Air conditioner
UN operatorOperationsmanager
Supervisor
Process engineer
Laboratory chemist
COMPONENTS AND EQUIPMENT OF SKU-10
Diesel generator
Cable reels
Coupling socketboard
SKU-10 MONITORING AND CONTROL STATIONSCHEDULE OF MONITORED AND LOGGED PARAMETERS OF THE FRACKING PROCESS
Time and pressure parameters- Date, time, Customer, Contractor, field, well, planned fracking parameters.- Pumping pressure 1 (BM-105), mPa. (max 85mPa)- Pumping pressure 2 (UN-2250), mPa (max 85 mPa)- Casing pressure, mPa (max 20 mPa)
Mixture flow rate and totalizers- Flow 1 at US mixer outlet, m3/min (max 15 m3/min)- Flow 2 at US mixer outlet, m3/min (max 15 m3/min)- Flow 3 at UN No. 1...4 pumping unit tachometers, m3/min (max 15 m3/min)- Mixture totalizer for flow 1 at outlet, m3
- Mixture totalizer for flow 2 at outlet, m3
- Mixture totalizer for flow 3 at tachometers, m3
Pure fluid flow and totalizers- Flow 1 at US inlet, m3/min- Flow 2 at US inlet, m3/min- Pure flow totalizer for flow 1 at US-10 inlet, m3- Pure flow totalizer for flow 2 at US-10 inlet, m3 - Total volume of pumped pure fluid from tanks, m3
Proppant concentration and totalizers- Proppant concentration 1 (acc. to density meter), kg/m3
- Proppant concentration 2, kg/m3
- Proppant totalizer 1, kg- Proppant totalizer 2, kg- Proppant totalizer 3, kg- Proppant delivery rate deriv. from rpm, screw conveyor
1 kg/min- Proppant delivery rate deriv. from rpm, screw conveyor 2 kg/min- Proppant delivery rate deriv. from rpm, screw conveyor 3 kg/min- Proppant totalizer, deriv. from rpm of screw conveyors 1, 2, 3 kg- Total mass of pumped proppant, kg Concentration of liquid and dry additives and totalizers- Flow rate of liquid additive 1, l/min- Flow rate of liquid additive 2, l/min- Totalizer for liquid additive 1, l- Totalizer for liquid additive 2, l- Delivery rate of dry additive. Screw conveyor 1, kg/min- Delivery rate of dry additive. Screw conveyor 2, kg/min- Totalizer for dry additive. Screw conveyor 1, kg- Totalizer for dry additive. Screw conveyor 2, kg- Total mass of pumped dry additive, kg
SKU-10 SOFTWAREMONITORING AND DIAGNOSTICS OF HYDROFRACKING PROCESS
SKU-10 SOFTWARERAW DATA INPUT GRAPHICAL REPRESENTATION OF HYDROFRACKING
REPORT GENERATION
UN-2250 PUMPING UNIT
UN-2250 PUMPING UNIT
The UN-2250 pumping unit is designed for the pumping of working fluid or working fluid–proppant mixtures into the well under pressure and with performance sufficient for hydraulic fracturing of deposits, and to effect hydraulic, sand jet, or chemical treatment of bottom-hole area at oil and gas fields. Climatic category “U1” (temperate climate, outdoors) GOST 15150-69.
The UN-2250 provides the following functionality:- Automated hydrofracturing operation
- Automated transmission gear shifting without breaking the power path and managing gas turbine engine operating modes.
- The common control panel allows smooth adjustment of SKU test pressure for manifolds and pump/compressor pipes, created by the UN in the 0...85 MPa range.
- 0...2.5 m3/min smooth adjustment range of UN pumping rate at the common control panel on the SKU.
- Automatic maintenance of constant pumping rate (regardless of the differential pressure caused by the well) on command from the common control panel to the SKU.
- Automated integrated monitoring of UN units and systems.
- Halting the pumping of working fluid into the well if maximum well pressure protection is tripped, without stopping the gas turbines.
UN-2250 PUMPING UNITTECHNICAL DETAILS
No. Parameters Values1 Chassis MAZ 6303A52 Total mass of the UN (operating weight), not more than 29600 kg3 Mass of the process equipment (operating weight), kg 19500 kg4 Power unit: two gas turbine engines with auxiliary systems in a monolithic unit.
4.1 Engine specification GTD-12504.2 Maximum power of one engine, h.p. 12504.3 Specific flow of fuel at maximum power, g/h.p.·h. 2354.4 Mass of a single engine in a monolithic unit (with systems), kg 15004.5 Fuel diesel fuel,
TS, RT5. Mechanical transmission with electric-hydraulic gear shifting, including two
planetary gearboxes and compound gear train.5.1 Number of gears in transmission 46. Plunger pump6.1 Model NTP-22506.2 Number of plungers 36.3 Plunger diameter, mm ( ) 127 (5.0)6.4 Maximum performance, m3/min 2.56.5 Maximum working fluid pressure, MPa 85
UN-2250 PUMPING UNITPERFORMANCE DIAGRAM
The diagram shows flow rates,at which the automated operating modes control system shifts gearsof KP1 and KP2
Fuel tank
GTD-1250gas turbine engines
NTP-2250 pump
Automatictransmission
Tank of the NTP-2250 power endlubrication system
EQUIPMENT OF THE UN-2250 PUMPING UNIT
Enginecontrol drive
EQUIPMENT OF THE UN-2250 PUMPING UNIT
Coupling
Air system tanks
Engine startupequipment
Rechargeablebatteries
Plunger seal lubrication system
REMOTE CONTROL PANEL OF THE UN-2250
Operational monitoringof systems
Switching of processmodes
Automated flow set point maintenance
Automatic overpressureprotection
Mon
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NTP-2250 PLUNGER PUMP
Maximum power: 2250 h.p.
US-10 BLENDER
The Mixing Unit is designed for preparing working fluids and mixtures as part of mobile systems for hydraulic fracturing and delivery of fluids and mixtures to the UN unit during hydraulic conditioning of the well bore area at oil fields.
The Mixing unit allows:- Automated operation in fluid, mixture preparation modes and hydrofracturing mode- Preparation of working fluids and mixtures using guar gum powder, activators,
thickeners, clay stabilizers, demulsifiers, crosslinkers, bulk chemicals, breakers, proppants- Adjustable supply of liquid chemicals when preparing working fluids and delivering
fluids and mixtures to the UN during hydrofracturing- Adjustable supply of breaker and proppant to the ingress bunker of the mixer during
hydrofracturing.
US-10 BLENDER
TECHNICAL DETAILS
No. Parameters Values1 Chassis (heavy duty semitrailer), model 946222 Fully loaded mass of the US (operating weight), kg 214003 Power unit
3.1 Engine specification YaMZ 3.2 Number of cylinders 123.3 Nominal power at 2100 min-1, kW (h.p.) 500 (680)4 Power takeoff mechanism with gear train, model AM450VD BD 3300
TECHNODRIVE5 Technical details of process equipment
5.1 Maximum process fluid flow rate, m3/min 105.2 Working gauge pressure in discharge header of the US, not less than,
MPa 0.2
5.3 Proppant delivery rate through the US mixer, t/min 0.1...65.4 Liquid additives flow rate, l/min 0.5...205.5 Dry additive (breaker) delivery rate: 5.6 - 1st range, kg/min 0.5...4.05.7 - 2nd range, kg/min 3.0...30.05.8 Bulk chemical (guar gum powder) delivery rate, kg/min 1.0...25.05.9 Maximum proppant concentration, kg/m3 1800
US-10 BLENDER
COMPONENTS AND EQUIPMENT OF US-10Diesel drive
Liquid additive tanks
Mixer
Proppant deliverymechanism
Aspirator pump
Controlled-volume pumps
Liquid additiveflow meters
COMPONENTS AND EQUIPMENT OF US-10
Dry additive introduction mechanism
Force pump
Electromagneticflow meter
Turbineflow meter
Densitymeter
US-10 CONTROL SYSTEM
The US-10 operation control system automatically provides:
- Scheduled flow of working fluids (mixtures) during preparation and hydrofracturing
- Scheduled flow of liquid additives during fluid and mixture preparation and delivery to
the UN unit
- Scheduled introduction of dry additives (breakers) into fluids and mixtures during
hydrofracturing
- Scheduled proppant concentration in the mixture during hydrofracturing
- Processing of instrument data and transmitting data to the SKU
If necessary, the operator may quickly switch to manual operation on the monitoring and
control panel in the US cabin.
US-10 MONITORING AND CONTROL PANEL
Hydraulic systemmonitoring
Operating parametersdisplay
YaMZ enginecontrol panel
Valvecontrol
US electric equipmentcontrol
Controlmodeswitch
Manualcontrol
of processequipment
US-10 CONTROL SOFTWARE INTERFACE
