Heater System for Cold Weather Hydraulic Fluid
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Solution Overview
Problem
Electrically powered hydraulic fracturing systems face challenges in maintaining hydraulic fluid from gelling at low temperatures, as they generate insufficient heat compared to diesel-powered systems, leading to operational issues at temperatures around 5°C and below.
Innovation Solution
Incorporation of a heater system, such as a tank with a heating element or thermal blanket, in thermal contact with the working fluid, powered by a turbine generator and transformers to provide necessary voltage for heating the hydraulic fluid, ensuring it remains fluid at lower temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If electric motors are used to power hydraulic fracturing pumps, then noise, emissions, and vibrations are reduced, but the system generates insufficient heat to prevent hydraulic fluid gelling at low temperatures
Solution Approach 1:
A heat exchanger is introduced as an intermediary component between the hydraulic fluid system and the heating system. The heat exchanger transfers thermal energy from the heating system to the hydraulic fluid, allowing the electrically powered system to maintain fluid temperature without requiring diesel engines or other high-heat-generating power sources.
2Temperature
If diesel engines are used to power hydraulic fracturing pumps, then sufficient heat is generated to warm hydraulic fluid, but the equipment size, mass, and complexity increase
Solution Approach 1:
The system is divided into separate functional modules: an electric motor for power generation, a heater for heat generation, and a heat exchanger for heat transfer. This segmentation allows each component to be optimized independently, replacing the integrated diesel engine system with smaller, more efficient separate units that collectively provide the same functions with reduced size and complexity.
3Device complexity
If hydraulic fluid is used in cold weather without heating, then the system operates with fewer components, but the fluid thickens and gelling occurs at temperatures around 5°C
Solution Approach 1:
The heating system activates before the hydraulic system operates in cold conditions, pre-heating the hydraulic fluid to above its gelling temperature. This preliminary thermal treatment ensures the fluid maintains proper flow characteristics throughout operation, preventing thickening and gelling issues that would compromise system reliability.
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 solution effectively prevents hydraulic fluid thickening by maintaining it above the gelling temperature, allowing the hydraulic fracturing system to operate efficiently in colder conditions without the need for additional heating sources, thus enhancing operational reliability and flexibility.
Implementation Method 1
a heater that is in thermal contact with the working fluid
Implementation Method 2
powered by a turbine generator and transformers
Data Source
AI summary
A hydraulic fracturing system includes an electrically powered pump that pressurizes fluid, which is piped into a wellbore to fracture a subterranean formation. System components include a fluid source, an additive source, a hydration unit, a blending unit, a proppant source, and a fracturing pump. The system includes heaters for warming hydraulic fluid and/or lube oil. The hydraulic fluid is used for operating devices on the blending and hydration units. The lube oil lubricates and cools various moving parts on the fracturing pump.