Power Distribution Trailer for Electric Fracking Pump Voltage Conversion
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Solution Overview
Problem
Conventional hydraulic fracking systems rely on multiple diesel engines and transmissions, leading to increased costs, parasitic losses, and operational inefficiencies, with diesel engines also causing noise pollution and difficulty meeting air quality standards.
Innovation Solution
Implementing an electric-driven hydraulic fracking system with a single VFD, single shaft electric motor, and single hydraulic pump on a trailer, powered by a centralized power generation system that includes gas turbine engines, reducing the need for multiple diesel engines and transmissions, and using a power distribution trailer to convert and distribute electric power efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple diesel engines and transmissions are used to drive hydraulic pumps, then the required horsepower can be achieved, but the operational costs increase and parasitic losses occur
Solution Approach 1:
The patent consolidates multiple diesel engines and transmissions into a single electric motor that drives all hydraulic pumps through a common power source. The electric motor is coupled to a common input shaft that connects to multiple hydraulic pumps, eliminating the need for separate diesel engines for each pump and reducing parasitic losses from multiple independent power trains.
Solution Approach 2:
The single electric motor serves multiple functions by simultaneously driving all hydraulic pumps required for the fracking operation. This universal power source replaces multiple specialized diesel engines, achieving the same total horsepower output while eliminating redundant mechanical components and reducing energy losses.
2Power
If multiple diesel engines are positioned at the fracking site, then the required power capacity is achieved, but the noise levels increase
Solution Approach 1:
The patent consolidates multiple noisy diesel engines into a single electric motor powered by an off-site power plant. This merging of power sources dramatically reduces noise levels at the fracking site while maintaining the required power capacity to drive all hydraulic pumps simultaneously.
3Productivity
If several hydraulic pumps are required to prepare the well, then the productivity is maintained, but the quantity of trailers and manpower increase
Solution Approach 1:
The patent integrates multiple hydraulic pumps onto a single trailer platform, sharing common components including the electric motor, transmission, and control systems. This consolidation maintains the productivity of having multiple pumps while reducing the number of separate trailers required and decreasing the manpower needed for setup and operation.
4Productivity
If diesel engines drive hydraulic pumps, then the pumping operation can be executed, but the air quality limits are difficult to meet
Solution Approach 1:
The patent replaces the mechanical diesel engine system with an electric motor system. The electric motor is powered by electricity transmitted from an off-site power plant through high-voltage cables, eliminating diesel combustion at the fracking site and thereby resolving air quality issues while maintaining full pumping operational capability.
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 system reduces operational costs, increases efficiency by minimizing parasitic losses, and enhances productivity by ensuring continuous pumping, while reducing noise and environmental impact.
Implementation Method 1
a power distribution trailer to convert and distribute electric power efficiently
Implementation Method 2
single VFD, a single shaft electric motor, and a single hydraulic pump positioned on a single pump trailer
Implementation Method 3
The single hydraulic pump may be positioned on the single pump trailer with the single VFD and the single shaft electric motor
Data Source
AI summary
An electric driven hydraulic fracking system is disclosed. A pump configuration that includes the single VFD, the single shaft electric motor, and the single hydraulic pump that is mounted on the single pump trailer. A power distribution trailer distributes the electric power generated by the power generation system at the power generation voltage level to the single VFD and converts the electric power at a power generation voltage level to a VFD voltage level and controls the operation of the single shaft electric motor and the single hydraulic pump. The power distribution trailer converts the electric power generated by the power generation system at the power generation level to an auxiliary voltage level that is less than the power generation voltage level. The power distribution trailer distributes the electric power at the auxiliary voltage level to the single VFD that controls an operation of the of the auxiliary systems.