Electric Fracturing Rig Power Control for Mixed Fleet Efficiency
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Solution Overview
Problem
Existing hydraulic fracturing systems with mixed fleets of mechanical and electric rigs face challenges in optimizing operations, leading to inefficiencies and wasted fuel or power resources.
Innovation Solution
A hydraulic fracturing system with a controller that optimizes the operation of both electric and mechanical rigs using a cost function and optimization algorithm, such as a particle swarm algorithm, to determine optimized operational parameters based on input data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a mixed fleet of mechanical and electric hydraulic fracturing rigs is used to achieve high flow rates, then productivity increases, but device complexity and difficulty of control increase
Solution Approach 1:
The patent combines multiple hydraulic fracturing rigs (both mechanical and electric) into a single coordinated fleet operated by one operator. The system merges the capabilities of different rig types while integrating their control through a centralized platform, allowing them to function as a unified system rather than isolated units.
Solution Approach 2:
The control system is designed to universally manage both mechanical and electric hydraulic fracturing rigs through a single operator interface. The system can adapt to different rig types and operational modes, providing multi-functional control capabilities that work across diverse equipment configurations.
2Adaptability or versatility
If multiple hydraulic fracturing rigs operate independently with different operational parameters, then adaptability increases, but loss of energy and fuel consumption increase
Solution Approach 1:
The system continuously monitors operational parameters across all rigs and uses this feedback to dynamically adjust and optimize performance. The control system receives real-time data from each rig, analyzes overall fleet efficiency, and makes coordinated adjustments to minimize energy consumption while maintaining operational flexibility.
Solution Approach 2:
The operational parameters of the hydraulic fracturing rigs are made dynamic rather than static. The system can adjust pressure, flow rate, and other parameters in real-time based on well conditions, equipment status, and efficiency optimization goals, allowing adaptive response to changing conditions without wasting energy.
3Adaptability or versatility
If a mixed fleet of hydraulic fracturing rigs is used, then adaptability to different well conditions improves, but ease of operation deteriorates
Solution Approach 1:
The control system provides universal operation capabilities that work across both mechanical and electric rig types through a single operator interface. This multi-functional design allows one operator to manage diverse equipment without needing separate control systems for each rig type, simplifying operation while maintaining adaptability.
Solution Approach 2:
The system merges the control functions of multiple different rig types into a unified operational interface. By combining control capabilities and presenting a consolidated interface to the operator, the system reduces the operational burden while maintaining the ability to adapt to different well conditions and equipment configurations.
Data Source
AI summary
A system may include one or more electric hydraulic fracturing rigs, a utility power source, a genset power group that includes gensets, and a site controller configured to receive a total power request for the one or more electric hydraulic fracturing rigs and control, based on a utility power request and a genset power request, the utility power source and the genset power group to power the one or more electric hydraulic fracturing rigs during a fracturing operation.