LabVIEW Reduces Emissions and Costs of Turbine-Engine Stimulation

Author(s):
David Gosnell - Turbine Stimulation Technologies

Industry:
Oil and Gas/ Refining/ Chemicals

Products:
LabVIEW, Compact FieldPoint

The Challenge:
Creating an easily expandable fracturing solution capable of improved functionality and cleaner emissions.

The Solution:
Using National Instruments LabVIEW software and NI Compact FieldPoint to reuse code and simplify setup time and complexity, while also allowing for future data communication plans.

Hydraulic Fracturing Stimulation Technologies

Hydraulic fracturing is a technique that allows oil or natural gas to move more freely from the rock pores where they are trapped, to a producing well that transports the oil or gas to the surface. After a well is drilled, it is important to maximize the production of oil and gas. One way to improve production is to connect many pre-existing fractures and flow pathways in the reservoir by making a larger fracture. This larger, man-made fracture starts at the well and extends out into the reservoir.

A hydraulic fracture is formed when a high pressure fluid is pumped down a well. The fluid is usually a mixture of water with special high-viscosity additives. When the fluid pressure exceeds the rock strength, a fracture opens in the rock. A propping agent, usually sand carried by the additives, is pumped into the fractures to prevent them from closing when the pumping pressure is released. The viscosity of the fluid lowers after a short period of time. Both the injected water and the now low-viscosity fluid travel back through the man-made fracture to the well and up to the surface.

Fracturing Equipment

When fracturing, there are several key components to the above-ground process, including blenders, pump trucks, and a data van. The blender is tasked with the crucial job of precisely proportioning fracturing fluid with a propping agent or sand. The hydration unit then holds the fluid that will be pumped into the ground to create the fracture. The pump trucks are large and can push fluid into the well at pressures approaching 15,000 psi. A data van controls and monitors all of the equipment being used in the fracturing process. This van is also used as a transmission point, where data can be sent back to the drilling company, drilling engineers, and customers who may want to look at the data in real time.

Turbine-Engine Fracturing Technology

Typical fracturing equipment requires large diesel engines to power the blenders, pumps, and other equipment. These engines are costly to operate, consume diesel gasoline less efficiently, and produce a high level of emissions. New fracturing technology uses smaller and more powerful turbine engines, reducing the amount of emissions and noise pollution while utilizing the existing transmission and pumping equipment.

Turbine engines can run on many different fuels, providing flexibility to select lower-cost and more readily available fuel sources. A traditional diesel engine used in fracturing creates about 1,500 hp and requires an entire trailer for transportation. A turbine engine, on the other hand, provides more horsepower per engine in about one-third the space. Three turbine engines can be transported on a single trailer, reducing capital equipment costs of trailers and operational costs of transportation and maintenance. The smaller number of trailers, trucks, and equipment also reduces the impact on the environment around the production well.

Implementing a Flexible Control System Based on LabVIEW and Compact FieldPoint

Turbine Stimulation Technologies (TST) and Marine Turbine Technologies (MTT)selected NI LabVIEW and Compact FieldPoint to control and monitor the fracturing process and equipment. LabVIEW monitors data such as exhaust gas temperatures, RPM, engine speed, oil pressure and temperature, fuel pressure, and fuel flow.

The pumping unit, blender, and data van use the same National Instruments hardware and software configuration. With the flexibility of LabVIEW, developers can reuse the hardware platforms they are familiar with and reuse code. Software designers can simply reuse existing control code between similar engines and between pumps and compressors.

Ethernet Reduces Time and Wiring Costs

Previous versions of fracturing control hardware used analog signals distributed from a central control van to drive distributed pumpers and blenders. This resulted in a significant amount of bundled wiring that was costly and difficult to install and maintain. With new Ethernet-based control platforms, we can distribute control systems using a single shielded Ethernet cord between Compact FieldPoint controllers and data van PCs, and industrial switches to route Ethernet traffic without collisions. This eliminates the need for excess wires, reduces costs, and dramatically reduces setup time on site for connecting all of the control and monitoring sensors and systems. Compact FieldPoint is a small, rugged system that we can easily distribute over an Ethernet network. Our designers can install Compact FieldPoint near the engines and the control points or inside the data van and connect between the two systems and industrial PCs.

Broadcasting Data to Remote Operators, Engineers, and Customers

LabVIEW is currently providing monitoring and control capabilities for turbine-engine powered stimulation systems. Future TST and MTT development plans take advantage of the LabVIEW Web capabilities and remote monitoring technology, so TST and MTT can offer real-time updates on fracturing jobs to the customer and remote operators. TST and MTT plan to broadcast fracturing data from the control van via satellite to the customer and remote operators, allowing customers to receive real-time updates and feedback on the fracturing job. Using these technologies, fracturing operators can save money by reducing travel expense for on-site reviews, and experienced operators and engineers can oversee multiple jobs in different locations from a central office. 

Combining the flexibility of LabVIEW with off-the-shelf rugged hardware platforms and new turbine engine fracturing technology provides TST and MTT with a rugged and efficient process and propulsion control system, while reducing development and deployment time in the field. LabVIEW supports easy integration of current programs to make larger applications by reusing code and hardware. LabVIEW also provides open connectivity to reduce wiring costs and connect remote operations to distributed operators, engineers, and customers. The result is more efficient and safer fracturing and stimulation operations, reduced emissions and costs, and the ability to provide customers with real-time information about their investment.

For more information, contact:

David Gosnell

Turbine Stimulation Technologies

N621 Blue Ash Dr.

Houston, Texas

Tel: 281-872-7900

Fax: 281-872-7901

E-mail: dgosnell@turbinestim.com

 

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