Integrated Fracking Skid Layout for Faster Wellsite Setup
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Solution Overview
Problem
Current wellsite equipment for hydraulic fracturing, or fracking, is complex and requires multiple pieces of equipment to be operatively coupled, leading to logistical challenges such as reconnection of cables and lines during setup, and lacks integrated solutions for efficient transportation and operation.
Innovation Solution
An integrated fracking system featuring a substructure assembly with frame rails, a pump subsystem, a variable frequency drive, a transformer, and a cooling subsystem, all coupled to the frame rails, which allows for transportability as a single unit and reduces the need for reconnection of cables and lines by housing them in cable trays, and includes features like vibration isolators and modular components for easier maintenance and configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple separate pieces of wellsite equipment are used for fracking operations, then functional requirements can be met, but setup complexity and operational complexity increase due to need for reconnection of cables and lines
Solution Approach 1:
The patent combines multiple separate wellsite equipment components (fracing pump, diesel motor, generator, heat exchanger, cable trays) into a single integrated fracking system mounted on a common skid or platform. This merging eliminates the need for complex reconnection of cables and lines during setup, as all components are pre-connected and transported as one unit, directly resolving the contradiction between operational simplicity and equipment complexity.
2Productivity
If multiple separate equipment pieces are used, then functional requirements are satisfied, but transportation logistics become more challenging
Solution Approach 1:
By integrating all fracking equipment onto a single skid or platform, the system transforms multiple separate transportation units into one consolidated transportable unit. This reduces logistical coordination requirements while maintaining full functional capability, thereby improving deployment efficiency without increasing transportation complexity.
Solution Approach 2:
The integrated system is designed as a modular skid-mounted unit that can be segmented for transport if needed, yet functions as a complete integrated system when assembled. This segmentation approach allows the system to be broken down into manageable transport sections while maintaining the ability to quickly reassemble and operate as a unified system, resolving the contradiction between deployment efficiency and logistical complexity.
3Ease of operation
If equipment is integrated into a single unit, then setup and transportation are simplified, but maintenance accessibility may be reduced
Solution Approach 1:
The integrated fracking system is designed with modular components mounted on the skid, where each major component (pump, motor, generator, heat exchanger) can be independently accessed and removed. This modular segmentation allows for quick setup as a unified system while maintaining ease of repair by enabling individual component access and replacement without disassembling the entire integrated unit.
Data Source
AI summary
An integrated fracking system includes a substructure assembly including one or more frame rails. The integrated fracking system includes a pump subsystem having a frac pump and a motor. The pump subsystem is coupled to the frame rails of the substructure assembly. The integrated fracking system includes a variable frequency drive, a transformer, and a cooling subsystem, each coupled to the frame rails of the substructure assembly.