Hybrid Powertrain Torque Distribution for Fracturing Pump Transients
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Solution Overview
Problem
Gaseous fuel engines used in hydraulic fracturing pumps exhibit poor transient response due to the long path between cylinders and fuel inlet, leading to inefficiencies in responding to fluctuating load demands, which can disrupt hydraulic fracturing operations.
Innovation Solution
A hybrid powertrain system that includes a gaseous fuel engine, a transmission, a driveshaft, a hydraulic fracturing pump, and a motor system, where a controller determines torque distribution between the engine and motor system to assist or brake the engine during transient events, ensuring optimal operation and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a gaseous fuel engine is used in a hydraulic fracturing pump system, then operational cost and emissions are reduced, but transient response performance deteriorates due to the long path between cylinders and fuel inlet
Solution Approach 1:
The patent combines a gaseous fuel engine with an electric motor system into a hybrid powertrain. The motor system compensates for the engine's slow transient response by providing immediate torque during load fluctuations, while the engine provides baseline power. This merging allows the system to maintain the cost and emission benefits of gaseous fuel operation while achieving fast transient response through motor assistance.
Solution Approach 2:
The hybrid controller acts as an intermediary that manages torque distribution between the gaseous fuel engine and the motor system. During transient events, the controller determines the optimal torque split, allowing the motor to bridge the response gap caused by the long fuel path in the gaseous fuel engine, thereby resolving the contradiction between operational efficiency and transient performance.
2Adaptability or versatility
If a gaseous fuel engine is used in a hydraulic fracturing pump system, then fuel availability and cleanliness are improved, but transient response to fluctuating load demands deteriorates
Solution Approach 1:
The hybrid powertrain merges the advantages of gaseous fuel operation (availability and cleanliness) with the rapid response characteristics of an electric motor. The motor system compensates for the gaseous fuel engine's inherent slowness in responding to load changes, making the system both environmentally friendly and operationally responsive.
Solution Approach 2:
The system dynamically adjusts torque distribution between the engine and motor based on real-time operating conditions. During transient load events, the controller increases motor torque contribution to maintain responsive operation, while allowing the gaseous fuel engine to operate efficiently during steady-state conditions, thus achieving both adaptability and ease of operation.
3Power
If torque is increased to meet fluctuating load demands, then power delivery is improved, but engine overspeed and operational instability occur due to poor transient response
Solution Approach 1:
The motor system serves as an intermediary that provides supplemental torque during transient load increases, allowing the gaseous fuel engine to meet power demands without overspeeding. The hybrid controller coordinates torque distribution to maintain operational stability while delivering the required power.
Solution Approach 2:
The hybrid controller continuously monitors engine operating conditions and adjusts torque distribution in real-time based on feedback from sensors. During transient events, the controller detects engine response delays and automatically increases motor torque contribution, preventing overspeed conditions and maintaining operational stability throughout the transient event.
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 hybrid powertrain system improves the transient response of gaseous fuel engines by dynamically adjusting torque distribution between the engine and motor system, maintaining steady flow rates and pressures during hydraulic fracturing, preventing engine overspeed, and optimizing operational efficiency.
Implementation Method 1
A motor system may be coupled to the hydraulic fracturing pump. The pump system may include a power source electrically connected to the motor system
Implementation Method 2
pumping hydraulic fracturing fluid into a wellbore at a rate and a pressure (e.g., up to 15,000 pounds per square inch (psi)) sufficient to form fractures
Implementation Method 3
a gaseous fuel (e.g., methane, natural gas, ethane, and/or propane) is burned in the engine
Data Source
AI summary
A pump system may include a hybrid powertrain that includes a gaseous fuel engine, a transmission coupled to the gaseous fuel engine, a driveshaft coupled to the transmission, a hydraulic fracturing pump coupled to the driveshaft, and a motor system coupled to the hydraulic fracturing pump. The pump system may include a power source electrically connected to the motor system. The pump system may include a controller configured to determine a torque distribution between the gaseous fuel engine and the motor system based at least in part on whether a transient event is associated with the pump system, and cause the gaseous fuel engine and the motor system to operate according to the torque distribution such that the motor system assists or brakes the gaseous fuel engine in driving the hydraulic fracturing pump.