Electric Fracturing Pump Drives for Stable Ancillary Unit Control
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Solution Overview
Problem
Hydraulic fracturing systems face issues with irregular control systems, reliability, environmental contamination, and inefficiencies due to the use of hydraulic power for ancillary units, leading to fluctuations in operation, multiple pump installations, and increased costs.
Innovation Solution
Transitioning to a system powered by electric motors with variable-frequency drives (VFDs) to operate ancillary units, eliminating hydraulic power sources, which allows for precise speed control and reduces the need for multiple pumps and hydraulic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hydraulic power is used to operate ancillary units, then mechanical power can be transmitted to multiple components, but the control system becomes irregular and operations fluctuate
Solution Approach 1:
The patent replaces the hydraulic power system with an electrical power system. Electric motors with VFDs provide mechanical power to ancillary units, eliminating the irregularities inherent in hydraulic control systems while maintaining reliable and stable operation across varying speed requirements.
Solution Approach 2:
The patent changes the control parameter from hydraulic pressure/flow to electrical frequency. By using VFDs to control motor speed through frequency modulation, the system achieves precise and stable control of ancillary units, eliminating the fluctuations caused by hydraulic charge pressure variations.
2Speed
If hydraulic motors are used to power chemical pumps, then pumps can operate at high speeds, but operation becomes unstable at low speeds
Solution Approach 1:
The patent replaces hydraulic motors with electric motors powered by VFDs. This substitution enables stable operation across the entire speed range, including low speeds, because electrical frequency control provides precise regulation without the surge and stall problems inherent in hydraulic motor operation at low flow rates.
3Adaptability or versatility
If multiple chemical pumps of different sizes are installed, then various fluid rates can be achieved, but device complexity and cost increase
Solution Approach 1:
The patent makes a single chemical pump universal by coupling it with a VFD-controlled electric motor. This allows the same pump to operate efficiently across a wide range of fluid rates by adjusting motor speed through frequency control, eliminating the need for multiple specialized pumps of different sizes.
Solution Approach 2:
The patent introduces dynamic speed control to the chemical pump system. Instead of using fixed-speed pumps selected for specific flow rates, the system uses a single pump with dynamically adjustable speed via VFD, allowing flexible adaptation to varying fluid rate requirements without changing hardware configuration.
4Power
If hydraulic systems are used, then power can be transmitted to remote components, but weight and environmental contamination increase
Solution Approach 1:
The patent replaces the hydraulic power transmission system with an electrical power transmission system. Electric motors and wiring eliminate the need for hydraulic fluid, thereby removing the risk of environmental contamination from hydraulic leaks while maintaining the capability to transmit power to remote ancillary components.
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 provides steady operation, reduces maintenance time and costs, enhances safety, and minimizes environmental impact by eliminating hydraulic fluids, while also reducing the overall size and weight of the equipment.
Implementation Method 1
Transitioning to a system powered by electric motors with variable-frequency drives (VFDs) to operate ancillary units
Implementation Method 2
one or more second motors, each of the one or more second motors electrically coupled to at least one of the one or more ancillary units to operate the at least one of the one or more ancillary units
Data Source
AI summary
The present disclosure is directed to a hydraulic fracturing system for fracturing a subterranean formation. In an embodiment, the system can include an electric pump fluidly connected to a well associated with the formation, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the formation and fractures the formation. The system can further include one or more ancillary units associated with the fluid pumped into the wellbore. The system can further include a first motor electrically coupled to the electric pump to operate the electric pump, and one or more second motors, each of the second motors electrically coupled to each of the ancillary units to operate the one or more ancillary units.