Hybrid Fracturing Fleet Power Control for Diesel-Electric Pump Coordination
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Solution Overview
Problem
Existing hydraulic fracturing fleets struggle to integrate diesel and electric equipment effectively, leading to operational inefficiencies and limitations in versatility and redundancy.
Innovation Solution
A hybrid fracturing fleet system that integrates diesel and electric equipment through a datavan with a multi-pump control station and switchgear, allowing seamless operation and control of both types of equipment using a controller and software module, enabling rapid replacement and load sharing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If diesel and electric equipment are integrated in a hybrid fleet, then operational flexibility and redundancy are improved, but system complexity and control difficulty increase
Solution Approach 1:
The hybrid fleet system is segmented into modular functional units (diesel-powered units, electric-powered units, datavans, pump stations) that can be independently controlled and managed. Each unit type has standardized interfaces and control protocols, allowing complex hybrid operations to be broken down into manageable segments that can be orchestrated through the centralized control system.
Solution Approach 2:
The control system is designed with universal functionality to manage both diesel and electric equipment through a single integrated platform. The datavan and control station can issue commands to, and monitor data from, multiple types of powered units using standardized communication protocols, eliminating the need for separate control systems for each power type.
2Adaptability or versatility
If multiple pump types (diesel and electric) are used simultaneously, then versatility in addressing different job requirements is improved, but coordination and control difficulty increase
Solution Approach 1:
The control system implements continuous feedback loops that monitor the operational status, performance metrics, and load conditions of all diesel and electric pumps. This real-time data allows the system to automatically adjust pump operations, balance loads between different power sources, and coordinate start/stop sequences to maintain optimal performance across the mixed pump fleet.
Solution Approach 2:
The pump coordination system is designed to be dynamic and adaptive, automatically adjusting operational parameters based on real-time conditions. The system can dynamically allocate work between diesel and electric pumps based on availability, efficiency requirements, and job specifications, rather than using fixed assignment protocols.
3Reliability
If rapid replacement of equipment is enabled for emergency situations, then operational continuity is improved, but preparation and response time requirements increase
Solution Approach 1:
The system implements preliminary action by pre-positioning backup equipment (both diesel and electric units) at strategic locations and pre-configuring replacement procedures. Equipment is staged and ready for rapid deployment, with pre-established communication channels and control protocols already in place, allowing immediate substitution when failures occur.
Solution Approach 2:
The control system enables rapid parameter changes when equipment is replaced, automatically adjusting operational settings, power distribution, and control parameters to match the characteristics of the replacement unit. This allows seamless transition between different equipment types without manual reconfiguration, significantly reducing response time.
Data Source
AI summary
A hydraulic fracturing system is disclosed as including a singular mobile platform of at least one mobile power unit (MPU) and at least one first switch gear that is configured to handle electric power from the MPU. The MPU is configured to generate voltage that matches the requirements of an electrical bus from the at least one switch gear such that a combined electrical current generated as a result of the generated voltage is provided to the electrical bus to the components of the hydraulic fracturing system. Further, the hydraulic fracturing system may include electrical fracturing equipment with at least one second switch gear to support the at least one first switch gear in handling electric power from the MPU. A datavan may be included in the system to control load shedding, load sharing, and power distribution for the electrical fracturing equipment comprising the at least one second switch gear.