Fixed Frequency Pump Drive Eliminates Variable Frequency Drive Complexity
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Solution Overview
Problem
Hydraulic fracturing operations require high-pressure and high-flow pumps, which are expensive and sensitive to downtime, necessitating reliable electric motors but existing systems are complex and prone to maintenance issues due to the use of variable frequency drives.
Innovation Solution
A hydraulic fracturing system utilizing a fixed-frequency electric motor powered by a motor control center without a variable frequency drive, coupled with a pump to inject fracturing liquids into earth formations, reducing equipment complexity and maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a variable frequency drive is used to control the electric motor, then the motor speed can be adjusted to match pumping requirements, but the system complexity and maintenance needs increase
Solution Approach 1:
The patent removes the variable frequency drive from the system entirely, extracting the problematic component that caused complexity and maintenance issues. The system achieves motor speed control through direct-on-line starting with fixed frequency power, eliminating the need for complex electronic control equipment while maintaining operational capability through pump-motor matching.
2Ease of operation
If a variable frequency drive is installed, then motor control precision improves, but equipment reliability decreases due to additional failure points
Solution Approach 1:
The patent eliminates the variable frequency drive component, removing the source of additional failure points. By using direct-on-line starting with fixed frequency power, the system reduces the number of electronic control components that could fail, thereby improving overall equipment reliability while maintaining sufficient operational control through proper pump-motor selection.
3Use of energy by moving object
If a variable frequency drive is used, then energy efficiency can be optimized, but the weight and cost of the system increase
Solution Approach 1:
The patent removes the variable frequency drive equipment, significantly reducing system weight and cost. The energy efficiency is maintained through proper matching of pump and motor specifications to the application requirements, eliminating the need for heavy electronic control equipment while achieving acceptable operational efficiency.
4Device complexity
If fixed frequency power is used directly, then system simplicity and reliability increase, but the ability to adjust motor speed decreases
Solution Approach 1:
The patent employs universal pump-motor combinations that are selected to match specific application requirements from the outset. By using direct-on-line starting with fixed frequency power, the system achieves simplicity and reliability while maintaining operational adaptability through proper initial selection of pump and motor specifications suited to the fracturing application.
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 configuration increases equipment reliability, eliminates maintenance costs associated with variable frequency drives, reduces weight and increases pumping capacity, while allowing for direct power supply without intermediate transformers, enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
an electric motor having a rotor coupled to the pump and a stator; and a motor control center configured to apply an alternating electrical voltage having a fixed-frequency to the stator in order to power the electric motor
Data Source
AI summary
An apparatus configured to hydraulically fracture an earth formation, includes a pump configured to hydraulically fracture the earth formation by pumping a fracturing liquid into a borehole penetrating the earth formation and an electric motor having a rotor coupled to the pump and a stator. A motor control center is configured to apply an alternating electrical voltage having a fixed-frequency to the stator in order to power the electric motor, wherein the apparatus and motor control center do not have a variable frequency drive.