Electric Fracturing Pump Control for Safe Downhole Pressure Waves

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Solution Overview

Problem

Current hydraulic fracturing processes require significant resources for monitoring downhole conditions using pressure pulse technology, and there is a need for efficient and safe management of electrical components to prevent damage from back EMF and voltage fluctuations during pumping rate changes.

Innovation Solution

A hybrid system combining a diesel engine and an electric pump motor, controlled by an information handling system, is used to manage torque requirements, reducing diesel fuel consumption and allowing for flexible mover usage, including natural gas engines, while minimizing torque fluctuations and preventing damage to electrical components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If pumping rate is reduced rapidly to generate pressure pulses for monitoring, then monitoring capability is improved, but electrical components may be damaged due to back EMF and voltage fluctuations

Engineering Contradiction:

Improvepressure pulse monitoring capabilityVSAvoidback EMF damage to electrical components

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

A variable frequency drive (VFD) is introduced as an intermediary device between the motor and pump. The VFD controls the motor speed and manages the transition during pump shutdown, preventing direct voltage spikes from reaching electrical components while still enabling rapid pump rate changes for pressure pulse generation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system pre-establishes control protocols and VFD settings before pump shutdown to cushion against back EMF effects. The VFD is configured to limit voltage fluctuations and manage motor braking during rapid deceleration, preventing damage before it occurs

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If diesel engines are used to provide torque during hydraulic fracturing, then power delivery is reliable, but diesel fuel consumption increases

Engineering Contradiction:

Improvepower delivery reliabilityVSAvoiddiesel fuel consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The system employs a hybrid power configuration where electric motors and diesel engines can operate independently or together. The variable frequency drive enables electric motors to provide torque during normal operation, reducing diesel consumption, while diesel engines remain available for backup power or high-torque requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system dynamically adjusts the operational parameters of power delivery by switching between electric and diesel power sources based on real-time demands. The VFD controls motor speed and torque output, optimizing fuel efficiency while maintaining reliable power delivery

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If electric pump motors are used to reduce diesel fuel consumption, then energy efficiency is improved, but torque fluctuations may damage electrical components

Engineering Contradiction:

Improvediesel fuel consumptionVSAvoidtorque fluctuations

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The variable frequency drive serves as a mediator that smooths out torque fluctuations generated by electric motors. It controls the motor's acceleration and deceleration rates, limiting sudden torque changes that could damage mechanical or electrical components while maintaining energy-efficient operation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system uses dynamic control through the VFD to adjust motor speed and torque output in real-time. This dynamic adjustment prevents abrupt torque fluctuations while maintaining the energy efficiency benefits of electric motor operation, allowing flexible adaptation to varying hydraulic fracturing demands

Inventive Principle:

Principle #15Dynamics

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 system enhances operational flexibility, reduces diesel fuel consumption, and safely manages torque transitions, ensuring the stability of electrical components during hydraulic fracturing operations.

Implementation Method 1

monitoring hydraulic fracturing, currently, requires a large number of resources to evaluate downhole conditions via pressure pulse technology

Methodology Applied

Scientific EffectPressure pulse technology:

Implementation Method 2

The development of subterranean operations and the processes involved in removing hydrocarbons from a subterranean formation are complex

Methodology Applied

Scientific EffectHydraulic fracturing:

Data Source

PatentUS20250369330A1Generating pressure tube waves downhole using electrical pumping units safely

Publication Date: 2025.12.04 HALLIBURTON ENERGY SERVICES INC

AI summary

A method for evaluating one or more properties of a wellbore. The method may include identifying a total power from all electric pump motors being used in a fracture operation, gradually reduce pump rates for one or more of the electric pump motors except for one or more selected electric pump motors. The method may further include gradually reduce the pump rate of the selected pump motors and stabilizing the pressure by holding the selected pump motors at a constant rate.