Fracturing Power Switchgear Layout for Blackout Protection
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Solution Overview
Problem
Existing electric power systems for hydraulic fracturing operations lack redundancy and effective blackout protection, leading to potential system failures and negative consequences such as screen outs, when a single turbine loses power.
Innovation Solution
A system comprising at least one primary generator and one backup generator, each connected to separate switchgear, allowing for independent operation. Additionally, a load shedding system monitors power draw and can shut down non-essential components to prevent overload, using a 4-20 mA signal to activate a breaker.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If all turbine generators are synced and tied together through a single switchgear point, then the system can share power resources, but the system loses redundancy and blackout protection
Solution Approach 1:
The patent divides the power system into separate segments with independent switchgear for each turbine generator. Each switchgear can independently control and protect its associated generators, preventing a single point of failure from taking down the entire system. This segmentation maintains power sharing capabilities while ensuring that if one turbine fails, others can continue operating independently.
2Productivity
If one turbine loses power in a synced system, then the remaining turbines must compensate, but the power draw overloads the turbines causing a shutdown of the entire system
Solution Approach 1:
The patent implements beforehand cushioning by pre-configuring the system with independent switchgear and load shedding capabilities. When one turbine fails, the system is already prepared to redistribute load and shed non-critical loads before the remaining turbines become overloaded. This prevents the cascade failure that would otherwise occur when remaining turbines cannot handle the sudden increased power demand.
3Power
If the system shuts down non-critical components to prevent overload, then turbine capacity is protected, but pumping operations may be interrupted
Solution Approach 1:
The patent applies local quality by selectively shutting down only non-critical components (such as auxiliary equipment) while maintaining power to critical pumping operations. The independent switchgear allows localized load shedding in specific areas of the system without affecting the core fracturing pumps, thus protecting turbine capacity while ensuring pumping operations continue uninterrupted.
Data Source
AI summary
A system for powering equipment used in a hydraulic fracturing operation, the system including at least one first generator in electrical communication with a first switchgear for providing power to primary components of a hydraulic fracturing operation, and at least one second generator in electrical communication with a second switchgear for providing power to backup components of a hydraulic fracturing operation. The at least one first generator is independent of the at least one second generator so that if the at least one first generator loses the ability to generate electricity, the at least one second generator can continue to generate electricity.