Electric Fracturing Pump Trailer Layout for Cable and Load Control
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Solution Overview
Problem
Hydraulic fracturing operations rely on diesel-powered equipment, which is costly, environmentally unfriendly, and logistically challenging due to the need for extensive transportation and potential safety hazards, while turbine-powered systems face inefficiencies at variable loads common in fracturing operations.
Innovation Solution
Development of an electric-powered hydraulic fracturing system with a consolidated trailer configuration, including a multi-plunger pump, variable frequency drive, transformer, and slide-out platform, to simplify mobilization, reduce cable congestion, and enhance safety by using electric motors and efficient power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If diesel-powered equipment is used for hydraulic fracturing operations, then sufficient power is available, but environmental harm increases and transportation logistics become more complex
Solution Approach 1:
The patent replaces diesel-powered mechanical engines with electric motors to power the fracturing pump. This substitution eliminates the combustion process and associated environmental harms (exhaust emissions, pollutants) while maintaining the required power output for hydraulic fracturing operations. The electric motor converts electrical energy directly to mechanical energy without combustion, resolving the contradiction between power availability and environmental harm.
2Power
If diesel-powered equipment is used for hydraulic fracturing operations, then sufficient power is available, but transportation and logistics become more challenging
Solution Approach 1:
The patent replaces heavy diesel engines with electric motors, which are lighter and require less infrastructure. The electric power system eliminates the need for diesel storage tanks, fuel delivery trucks, and refueling operations, significantly simplifying transportation logistics and ease of operation while maintaining full power capability for fracturing operations.
3Object-affected harmful factors
If turbine generators are used to power fracturing operations, then environmental friendliness improves, but operational efficiency decreases at variable loads
Solution Approach 1:
The patent employs a variable frequency drive (VFD) system with microprocessor control that dynamically adjusts the electric motor's operating parameters to match the actual load requirements of the fracturing pump. This dynamic control maintains high operational efficiency across varying load conditions while preserving the environmental benefits of electric power, resolving the contradiction between environmental friendliness and productivity.
4Object-affected harmful factors
If electric-powered systems are implemented, then safety and environmental impact improve, but system complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single electric-powered fracturing system, including the fracturing pump, variable frequency drive, transformer, and control systems all mounted on one trailer. This consolidation reduces the number of separate components and connections needed, thereby reducing overall system complexity while maintaining the safety and environmental advantages of electric power.
5Ease of operation
If consolidated trailer configuration is used, then mobility improves and cable congestion is reduced, but device complexity increases
Solution Approach 1:
The patent combines the fracturing pump, variable frequency drive, transformer, and control systems into a single integrated trailer unit. This merging of components improves mobility by eliminating the need for multiple separate trailers and reduces cable congestion by consolidating electrical connections within one unit. The integrated design manages device complexity through systematic arrangement and standardized interfaces.
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 electric-powered system improves mobility, reduces logistical challenges, and enhances safety by minimizing cable hazards and environmental impact, while maintaining efficient operation across varying load conditions.
Implementation Method 1
a variable frequency drive, arranged in the second area proximate the first area, connected to the at least one electric motor to control the speed of the at least one electric motor
Implementation Method 2
a transformer, arranged in the third area proximate the second area, the transformer positioned within an enclosure, the transformer distributing power to the electric powered pump, the power being received from at least one generator at a voltage higher than an operating voltage of the electric powered pump
Data Source
AI summary
A hydraulic fracturing system for fracturing a subterranean formation includes a support structure that includes an electric powered pump, arranged in a first area, the electric powered pump powered by at least one electric motor, also arranged in the first area. The system further includes a variable frequency drive (VFD), arranged in a second area proximate the first area, connected to the at least one electric motor to control the speed of the at least one electric motor. The system includes a transformer, arranged in a third area proximate the second area. The system also includes a slide out platform integrated into the first area, the slide out platform being driven between a retracted position and a deployed position.