Electric Hydraulic Fracking Pump Layout for Continuous High-HP Operation
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Solution Overview
Problem
Conventional hydraulic fracking systems rely on diesel engines, which increase costs, require multiple trailers and manpower, generate noise, and suffer from parasitic losses, limiting efficiency and productivity.
Innovation Solution
An electric-driven hydraulic fracking system utilizing a single Variable Frequency Drive (VFD), single shaft electric motor, and single hydraulic pump on a single trailer, powered by a consolidated power generation system, reducing the need for multiple diesel engines and transmissions, and incorporating gas turbine engines or an electric utility grid for efficient power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple diesel engines and hydraulic pumps are used to increase power rating, then the horsepower available for hydraulic pumps increases, but the quantity of trailers, manpower, and operational costs increase significantly
Solution Approach 1:
The patent consolidates multiple diesel engines and hydraulic pumps into a single integrated electric motor-driven hydraulic pump system. The electric motor is directly coupled to the hydraulic pump, eliminating the need for separate diesel engines and transmissions for each pump, thereby reducing the number of trailers and equipment while maintaining the required power output.
Solution Approach 2:
The single electric motor serves multiple functions by directly driving the hydraulic pump and powering auxiliary systems through a single integrated power source. This multi-functional approach replaces the need for multiple specialized diesel engines, reducing overall system complexity and equipment quantity.
2Power
If multiple diesel engines are positioned at the fracking site to drive hydraulic pumps, then the power requirement is met, but the noise levels increase and air quality limits may not be satisfied
Solution Approach 1:
The patent replaces the mechanical combustion-based diesel engine system with an electric motor system. This substitution eliminates the noise and emissions associated with diesel combustion while providing the same or greater power output to drive the hydraulic pump, thereby resolving the harmful effects of noise and air quality degradation.
3Power
If diesel engines drive hydraulic pumps and auxiliary systems, then power is provided to all systems, but parasitic losses occur that decrease the horsepower available for hydraulic pumps
Solution Approach 1:
The patent extracts the parasitic losses associated with diesel engine operation by removing the diesel engine and transmission components. The electric motor directly drives the hydraulic pump without the intermediate mechanical losses of diesel combustion and transmission, thereby eliminating parasitic energy losses and maximizing the horsepower available for the hydraulic pump.
4Power
If several hydraulic pumps are required to attain the required horsepower, then the power requirement is met, but the quantity of trailers and manpower required increases
Solution Approach 1:
The patent merges multiple hydraulic pump functions into a single high-power hydraulic pump driven by an electric motor. This consolidation reduces the quantity of hydraulic pumps from multiple units to a single unit, thereby reducing the number of trailers and manpower required while maintaining the total horsepower output needed for the fracking operation.
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, reduces noise levels, minimizes parasitic losses, and enhances productivity by maintaining continuous operation of hydraulic pumps, thereby increasing the efficiency of fracking operations.
Implementation Method 1
An electric-driven hydraulic fracking system utilizing a single Variable Frequency Drive (VFD), single shaft electric motor, and single hydraulic pump on a single trailer
Implementation Method 2
single shaft electric motor
Implementation Method 3
single hydraulic pump positioned on a single pump trailer that continuously pumps the fracking media into the well
Data Source
AI summary
An electric driven hydraulic fracking system is disclosed. A pump configuration that includes the single VFD, the single shaft electric motor, and the single hydraulic pump that is mounted on the single pump trailer. The single VFD converts the electric power of at least 13.8 kV to a VFD rated voltage level of at least 4160 V and drives the single shaft electric motor at the VFD voltage level of up to 4160 V to control the operation of the single shaft electric motor and the single hydraulic pump. The single shaft electric motor drives the single hydraulic pump with the rotation at the rated RPM level of at least 750 RPM. The single hydraulic pump continuously pumps the fracking media into the well at the HP level of at least 5000 HP. The single hydraulic pump operates on a continuous duty cycle to continuously pump the fracking media at the HP level of at least 5000 HP.