Electric Fracturing Valve Actuation for Remote Pressure-Zone Control
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Solution Overview
Problem
Hydraulic fracturing operations face challenges with diesel-powered systems, including environmental hazards, safety concerns, and inefficiencies, while turbine systems struggle with fluctuating loads and large footprints, limiting access to high-pressure zones and increasing downtime due to manual valve control in hazardous areas.
Innovation Solution
A modular switchgear system and power distribution for electric oilfield equipment, featuring remotely controllable electric actuators for hydraulic fracturing valves, allowing safe and efficient operation from a distance, reducing the need for manual intervention and minimizing equipment damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual valve control is used in high-pressure zones, then valve operation can be performed, but operator safety is compromised and access is limited
Solution Approach 1:
The patent replaces manual mechanical valve operation with an automated electric actuator system. The electric actuator receives control signals from a remote location and automatically actuates the valve, eliminating the need for operators to physically access high-pressure zones. This substitution of mechanical manual operation with an electromechanical automated system resolves the safety contradiction.
Solution Approach 2:
The patent introduces an intermediary control system consisting of an electric actuator and remote control interface. This intermediary mechanism allows valve operation to be performed from a safe distance, mediating between the operator and the hazardous high-pressure environment. The actuator serves as the intermediary that performs the physical valve operation without requiring direct operator presence in the danger zone.
2Power
If diesel-powered systems are used for fracturing operations, then sufficient power is available, but environmental hazards and safety concerns increase
Solution Approach 1:
The patent changes the fundamental energy source parameter from diesel (fossil fuel combustion) to electric power (clean energy). This parameter change in the power source eliminates harmful emissions while maintaining sufficient power availability for fracturing operations. The electric actuator system operates on electrical energy, fundamentally changing the energy input characteristics to remove environmental hazards.
3Object-generated harmful factors
If turbine generators are used to power fracturing operations, then environmental impact is reduced, but efficiency decreases under fluctuating loads
Solution Approach 1:
The patent segments the power system into multiple independent electric actuators, each capable of operating independently. This segmentation allows the system to handle fluctuating loads more efficiently by activating only the necessary number of actuators based on actual demand, rather than requiring a single large turbine to operate at constant high efficiency. Each actuator can be sized and controlled independently to match specific valve requirements.
4Object-affected harmful factors
If electric actuators are remotely controlled, then operator safety is improved, but control system complexity increases
Solution Approach 1:
The patent designs the electric actuator with multi-functionality, integrating multiple capabilities into a single device. The actuator incorporates position sensing, control signal reception, valve actuation, and status feedback functions within one unified component. This universal design reduces overall system complexity compared to having separate components for each function, while maintaining remote control capability for operator safety.
Data Source
AI summary
A hydraulic fracturing valve control system includes an electric powered, multi-plunger hydraulic fracturing pump. The system also includes a manifold coupled to the hydraulic fracturing pump. The system further includes a valve associated with the manifold, the valve being operable to move between an open position, a closed position, and a plurality of intermediate positions. The system includes a valve actuator, coupled to the valve, the valve actuator being an electric actuator that is remotely controllable in response to one or more operational aspects of the hydraulic fracturing pump. The system also includes a control interface, the control interface forming at least a portion of a control system, the control interface being accessible from a location remote from the hydraulic fracturing pump and outside of a zone of pressure formed by the hydraulic fracturing pump during operation.