Blender Power Unit Layout for Reduced Fracturing Cable Complexity
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Solution Overview
Problem
The increasing complexity and size of fracturing equipment spreads in well stimulation jobs are hindered by the large number of electric power cables required, which complicates power distribution and increases capital costs.
Innovation Solution
A blender power unit (BPU) that receives power from a single electric power cable and distributes it to multiple electric motors, reducing the number of cables needed and allowing for flexible power sourcing, including both electric grid power and diesel-generated power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric power cables are routed from a power distribution unit to each main electric power consuming motor, then each motor receives dedicated power, but the number of cables increases and system complexity increases
Solution Approach 1:
The patent combines multiple cable functions into a single cable by introducing a mobile power unit that acts as an intermediate power distribution node. This single cable connects the stationary power distribution unit to the mobile power unit, which then distributes power to multiple motors, thereby reducing the total number of cables from the stationary unit while maintaining dedicated power delivery to each motor.
Solution Approach 2:
The mobile power unit serves as an intermediary between the stationary power distribution unit and the multiple motors. It receives power from the stationary unit via a single cable and redistributes it to various motors, simplifying the cable infrastructure while ensuring reliable power delivery to each motor through the intermediary's distribution network.
2Reliability
If multiple electric power cables are routed from the power distribution unit to multiple motors, then each motor has dedicated power supply, but capital costs increase due to more cables
Solution Approach 1:
The patent merges multiple cable connections into a single cable connection by introducing the mobile power unit as a centralized power distribution point. Instead of running separate cables from the stationary power distribution unit to each motor, all cables converge at the mobile power unit, significantly reducing the total cable quantity and associated capital costs while maintaining dedicated power supply to each motor.
3Power
If a large number of electric power cables are used in the fracturing equipment spread, then power can be delivered to all motors, but the system becomes increasingly complex and difficult to manage
Solution Approach 1:
The patent segments the power distribution system into two functional parts: a stationary power distribution unit and a mobile power unit. This segmentation allows the system to maintain high power distribution capacity while reducing overall complexity by localizing power distribution functions at the mobile unit, which can be positioned close to the motors it serves.
Solution Approach 2:
The mobile power unit acts as an intermediary that simplifies the power distribution architecture. It receives power from the stationary unit through a single cable and handles the complex task of distributing power to multiple motors, thereby reducing the complexity at the stationary unit while maintaining the necessary power distribution capacity throughout the system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The BPU simplifies power distribution, reduces cable complexity, and lowers capital costs by enabling efficient power delivery to multiple motors, while providing flexibility in power sourcing options.
Implementation Method 1
a step-down transformer having an input and an output and configured to receive electrical power via the input at a first voltage from a power distribution unit (PDU), from a turbine driven generator, from a diesel driven generator, or from a grid power source and to output electrical power via the output at a second voltage that is lower than the first voltage
Data Source
AI summary
A blender power unit (BPU) for use in fracturing jobs. The BPU comprises a transformer having an input and an output and configured to receive electrical power via the input at a first voltage to output electrical power via the output at a second voltage; a motor power bus coupled to the output of the transformer; a motor starter bus; at least one motor soft starter having an input coupled to the motor power bus and having an coupled to the motor starter bus; a plurality of electric power relays coupled to the motor power bus and configured to supply electric power from the motor power bus to a load when in a closed state; and a plurality of start electric power relays coupled to the motor starter bus and configured to supply electric power from the motor starter bus to a load when in a closed state.