Hydraulic Pumping System Control for Fracking Energy Efficiency

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Solution Overview

Problem

Hydraulic pumping systems used in fracking face inefficiencies due to continuous operation of the pump motor during rest periods, leading to energy wastage and increased wear, and the use of electrical heaters requires expensive and short-lived accumulators.

Innovation Solution

A method for controlling a hydraulic pumping system that determines the current and expected operating modes to optimize the operation of the motor and accumulator, allowing for efficient shutdown and reduced energy consumption, using a fuel-driven drive with a heating device and charge control, which influences operating values such as heating levels and charging power based on anticipated usage patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the pump motor is switched off during rest periods, then energy efficiency is improved, but the motor experiences cold start wear and potential warranty loss

Engineering Contradiction:

Improveenergy efficiencyVSAvoidmotor wear and warranty

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The system performs preliminary heating of the motor during the preceding production phase before switching off, ensuring the motor is already warm when shutdown occurs. This preliminary action prevents cold start wear while allowing energy-efficient shutdown during rest periods.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The heating device is activated in advance to counteract the upcoming cooling effect that would occur after shutdown. By applying heat before the harmful cooling happens, the system prevents the motor temperature from dropping below the critical threshold during rest periods.

Inventive Principle:

Principle #9Preliminary anti-action

2Reliability

If the motor remains running during rest periods, then motor temperature is maintained, but energy is wasted

Engineering Contradiction:

Improvemotor temperature maintenanceVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

Instead of continuous operation, the system uses periodic action by switching the motor off during rest periods and restarting only when needed. The heating device provides periodic thermal maintenance during shutdown, enabling energy-efficient intermittent operation while preserving motor readiness.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The heating function is extracted as a separate device that can operate independently during shutdown periods. This allows the motor to be completely switched off for energy savings while the standalone heating device maintains temperature when required, separating the thermal maintenance function from continuous motor operation.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If an electrical heater is used to maintain motor temperature, then motor wear is reduced, but accumulator cost and replacement frequency increase

Engineering Contradiction:

Improvemotor protection from cold startVSAvoidaccumulator service life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The heating device operates at partial capacity during production phases rather than full power continuously. By providing just enough heat to maintain minimum temperature during shutdown periods rather than excessive heating, the energy demand on the accumulator is reduced, extending its service life while still protecting the motor.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The heating device is activated in advance during production phases to prepare the motor for upcoming shutdown periods. This preliminary heating reduces the total heating duration needed during rest periods, thereby reducing cumulative energy consumption from the accumulator and extending its operational life.

Inventive Principle:

Principle #10Preliminary action

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

This approach enhances energy efficiency, reduces maintenance costs, and extends the life of the accumulator, enabling cost savings while maintaining system readiness and preventing cold start-related wear.

Implementation Method 1

a heating device for heating the motor

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

an accumulator with a charge control system

Methodology Applied

Scientific EffectEnergy storage: Accumulator (energy)

Data Source

PatentUS10358989B2Method for controlling a hydraulic pumping system, and corresponding control device and pumping system

Publication Date: 2019.07.23 EKU POWER DRIVES

AI summary

Method for controlling a hydraulic pumping system that is stationary while in operation, the pumping system comprising a fuel-driven drive with a motor for a pump, a heating device for heating the motor and an accumulator with a charge control, the method comprising the steps of: detecting at least a first operating value, determining a current and an expected operating mode, and influencing at least a second operating value. Further, a control device for a hydraulic pumping system that is stationary while in operation, and a hydraulic pumping system that is stationary while in operation are also provided.