Electric Fracking Pump Control for Continuous Pumping
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Solution Overview
Problem
Conventional hydraulic fracking systems rely on diesel engines, leading to increased costs, noise pollution, and operational inefficiencies due to the need for multiple diesel engines, transmissions, and trailers, which also result in parasitic losses and extended operation durations.
Innovation Solution
An electric-driven hydraulic fracking system utilizing a single Variable Frequency Drive (VFD), single shaft electric motor, and single hydraulic pump positioned on a single pump trailer, powered by a consolidated power generation system, reducing the number of gas turbine engines and medium voltage cables, and incorporating a sophisticated control system for real-time operation optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple diesel engines and transmissions are used to drive multiple hydraulic pumps, then the required horsepower is achieved, but the device complexity and quantity of assets increase significantly
Solution Approach 1:
The patent consolidates multiple diesel engines, transmissions, and hydraulic pumps into a single integrated electric-driven hydraulic pump system. This merging reduces the number of separate assets from multiple engines and transmissions to one electric motor and one hydraulic pump, while maintaining the required total horsepower through a single high-power electric motor coupled directly to the pump.
Solution Approach 2:
The single electric-driven hydraulic pump system performs the function previously distributed across multiple diesel engine-transmission-pump combinations. The universal electric motor can be sized to provide the aggregate horsepower of all previous diesel engines, eliminating the need for multiple specialized powertrain assemblies while achieving the same operational capability.
2Power
If multiple diesel engines and trailers are positioned at the fracking site, then the required power and pumping capacity are achieved, but the ease of operation and manpower requirements increase
Solution Approach 1:
The patent merges multiple trailer-based power and pumping units into a single integrated electric-driven pump unit. This consolidation reduces the number of trailers from multiple to one, thereby reducing the number of CDL drivers and rigging personnel needed to operate and position the equipment at the fracking site.
Solution Approach 2:
The electric-driven system with direct coupling eliminates the need for transmission operation and multiple engine management tasks that previously required skilled operators. The simplified single-motor system reduces operational complexity and manpower needs for system management and coordination.
3Productivity
If diesel engines are used to drive hydraulic pumps, then the pumping operation is maintained, but parasitic losses occur that decrease the available horsepower
Solution Approach 1:
The patent replaces the mechanical diesel engine-transmission system with an electric motor system. This substitution eliminates parasitic losses associated with diesel engine auxiliary systems (cooling, lubrication, fuel injection) and transmission mechanical losses. The electric motor provides direct drive to the hydraulic pump with minimal energy loss, maximizing the horsepower available for actual pumping operations.
4Power
If multiple trailers are used to transport and position the fracking equipment, then the required power and pumping capacity are transported, but the ease of manufacture and deployment cost increase
Solution Approach 1:
The patent combines multiple separate trailer units (each carrying a diesel engine and hydraulic pump) into a single trailer configuration carrying the electric-driven hydraulic pump system. This merging reduces the number of trailers from multiple to one, thereby reducing transportation costs, deployment complexity, and the number of permits and CDL drivers required.
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
This solution decreases operational costs, minimizes noise, enhances productivity by maintaining continuous pumping, and reduces the asset count and manpower requirements, while eliminating parasitic losses and allowing for efficient power distribution and control.
Implementation Method 1
a single Variable Frequency Drive (VFD), a single shaft electric motor, and a single hydraulic pump positioned on a single pump trailer
Data Source
AI summary
An electric driven hydraulic fracking system is disclosed. A pump configuration includes the single VFD, the single shaft electric motor, and the single hydraulic pump mounted on the single pump trailer. A controller associated with the single VFD and is mounted on the single pump trailer. The controller monitors operation parameters associated with an operation of the electric driven hydraulic fracking system as each component of the electric driven hydraulic fracking system operates to determine whether the operation parameters deviate beyond a corresponding operation parameter threshold. Each of the operation parameters provides an indicator as to an operation status of a corresponding component of the electric driven hydraulic fracking system. The controller initiates corrected actions when each operation parameter deviates beyond the corresponding operation threshold. Initiating the corrected actions when each operation parameter deviates beyond the corresponding operation threshold maintains the operation of the electric driven hydraulic fracking system.