Hydraulic Fracturing System Segmentation for Weight Reduction
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Solution Overview
Problem
Existing hydraulic fracturing systems rely on heavy diesel-powered pumps that are inefficient and require high maintenance, making them costly and difficult to transport between oilfields.
Innovation Solution
A self-contained system featuring a trailer and tractor unit with electric induction motors and variable frequency drives, powered by diesel generators, capable of delivering high horsepower and reducing the overall weight and footprint for efficient fracturing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If diesel-powered pumps are used to deliver high pressure fracturing fluid, then sufficient power and pressure are achieved, but the system becomes excessively heavy and requires heavy duty trailers for transport
Solution Approach 1:
The system is divided into separate functional modules: electric induction motors mounted on the trailer unit, diesel generators mounted on the tractor unit, and pump systems. This segmentation allows the heavy power generation component (diesel generator) to be separated from the pump system, enabling transport on lighter trailers while maintaining sufficient power delivery through the electrical connection between tractor and trailer units.
2Power
If diesel-powered pumps are used for high pressure fracturing, then required power output is achieved, but maintenance requirements increase significantly
Solution Approach 1:
The direct mechanical coupling of diesel engines to pump systems is replaced with an electrical power transmission system. Electric induction motors mounted on the trailer receive power from diesel generators on the tractor through electrical connections, eliminating the need for complex mechanical transmissions and reducing maintenance requirements while maintaining high power output capability.
3Power
If diesel-powered pumps are used to achieve high pressure fracturing, then sufficient horsepower is delivered, but transportation cost and efficiency decrease
Solution Approach 1:
The system separates the heavy diesel generator (power source) from the pump system, allowing the pump system to be mounted on lighter trailers that can be transported more efficiently between sites using standard transportation infrastructure, while the diesel generator remains on the tractor unit that provides power through electrical connection.
Solution Approach 2:
The tractor unit serves dual functions: it provides transportation for the operator and equipment, and simultaneously serves as a mobile power plant through the diesel generator that can power multiple trailer units at different locations, increasing overall system utilization and reducing the need for dedicated power sources at each site.
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
The system provides efficient and reliable fracturing capabilities with reduced weight and maintenance needs, allowing for more efficient transportation and operation, while maintaining high power delivery to the fracturing site.
Implementation Method 1
diesel generator coupled to the motors and VFD
Implementation Method 2
one or more induction motors with cooling fans, the one or more electric induction motors being coupled to the well service pumps
Implementation Method 3
one or more induction motors with cooling fans, one or more variable frequency drives (VFD) with a cooling system
Data Source
AI summary
A pumping system for use in hydraulic fracturing or fracing of wells. The pumping system is generally self-contained on a transportable system, such as a trailer. The weight and configuration of the trailer must be sized to be hauled legally on United States roadways. The system components include a diesel generator with cooling radiator, a variable-frequency drive (VFD) with cooling system, an A/C induction motor and a high capacity pump. The system may also include a second generator to power other items, such as cooling fans, cooling pumps, lube pumps, lighting and electrical outlets and air conditioning units for cooling equipment. In some embodiments, the system includes single components, while other embodiments include redundant components.