Fracturing Spread Power Blackout Prevention

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Solution Overview

Problem

Hydraulic fracturing operations are at risk of power blackouts due to insufficient power supply from units like generators or the electric grid, leading to increased non-productive time, potential damage to equipment, and prolonged restart times.

Innovation Solution

Implement a control system that continuously monitors the available capacity of power units and the actual power usage of electric pumps, comparing these to determine if a power blackout is imminent. If so, the system generates and executes actions such as reducing pump flow rates or adjusting chemical concentrations to mitigate the risk of a power blackout.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the electric pumps increase flow rate to maintain productivity during hydraulic fracturing, then the productivity is improved, but the power consumption increases beyond available capacity causing power blackout

Engineering Contradiction:

Improveflow rateVSAvoidpower consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The control system continuously monitors power consumption of electric pumps and available power capacity, comparing real-time data to detect when power consumption approaches available capacity. This feedback loop enables proactive reduction of pump flow rates before power blackout occurs, resolving the contradiction between maintaining productivity and avoiding excessive power consumption

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary action by detecting potential power blackout conditions before they occur and automatically reducing pump flow rates in advance. This preemptive measure prevents power blackout while maintaining productivity as closely as possible, addressing the contradiction between high flow rate requirements and power consumption limits

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the pumps operate at high power consumption to maintain fracturing operations, then the productivity is improved, but the reliability decreases due to power blackout risk

Engineering Contradiction:

Improvefracturing operations continuityVSAvoidpower supply stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The control system uses continuous feedback monitoring of power consumption versus available capacity to maintain reliable operation. By detecting when power consumption approaches available capacity thresholds, the system can take corrective action to prevent power blackout, thereby maintaining both productivity and reliability simultaneously

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system applies beforehand cushioning by maintaining a safety margin between actual power consumption and available power capacity. This cushioning buffer prevents power blackout by ensuring power consumption does not exceed available capacity even under varying operational conditions, thus protecting reliability while allowing high productivity

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Productivity

If power units are restarted after blackout to resume operations, then the productivity is restored, but the loss of time increases due to restart duration

Engineering Contradiction:

Improveoperations resumptionVSAvoidrestart time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The control system performs preliminary action by detecting potential power blackout conditions before they occur and automatically reducing pump flow rates to prevent blackout. This prevents the need for restart operations entirely, eliminating restart time loss and maintaining continuous productivity

Inventive Principle:

Principle #10Preliminary action

4Ease of operation

If the pumps operate without coordinated control to maintain individual performance, then the ease of operation is improved, but the power consumption becomes unbalanced causing power blackout

Engineering Contradiction:

Improvepump operation independenceVSAvoidtotal power consumption

Core Design Contradiction:

Ease of operationVSUse of energy by moving object

Solution Approach 1:

The control system merges the control of multiple electric pumps under a single coordinated system that monitors total power consumption against available power capacity. This coordinated control balances power consumption across all pumps, preventing any single pump from consuming excessive power that could cause blackout, while maintaining ease of operation through automated control

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250163906A1Preventing power blackout while fracturing

Publication Date: 2025.05.22 HALLIBURTON ENERGY SERVICES INC

AI summary

A method for preventing a power blackout of a fracturing spread configured to hydraulically fracture a subsurface formation. The method comprises determining an available capacity of one or more power units that supply power to one or more electric pumps of the fracturing spread. The method comprises determining an actual power usage of the one or more electric pumps. The method comprises determining if the fracturing spread is at risk of the power blackout based on the available capacity and the actual power usage. The method comprises determining one or more actions to mitigate the power blackout; and executing the one or more actions to mitigate the power blackout.