Integrated Enclosure Cooling for Direct Drive Unit Heat Rejection
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Solution Overview
Problem
Existing cooling systems for direct drive units (DDUs) in hydraulic fracturing operations are inefficient, leading to significant heat rejection and energy loss, which affects temperature-sensitive components and requires large cooling packages, increasing the physical footprint and power consumption.
Innovation Solution
An enclosure assembly with integrated heat exchanger assemblies, intake and outlet fan systems, and temperature sensors and controllers to manage airflow and maintain optimal temperature, minimizing energy loss and footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling systems are used for direct drive units, then cooling function is provided, but physical footprint and power consumption increase
Solution Approach 1:
The patent combines the cooling system components (heat exchangers, fans, airflow paths) directly into the enclosure structure housing the direct drive unit. The heat exchangers are integrated onto the enclosure walls, and fan assemblies are mounted within the same enclosure space, creating a unified cooling package that reduces overall physical footprint while maintaining effective cooling of the direct drive unit.
2Temperature
If traditional cooling systems are used for direct drive units, then cooling function is provided, but power consumption increases
Solution Approach 1:
The patent employs controllers that activate fan assemblies and heat exchangers based on temperature sensor feedback, creating periodic or demand-based cooling operation rather than continuous operation. The system monitors temperatures within the enclosure and activates cooling components only when thermal thresholds are exceeded, reducing overall power consumption while maintaining adequate cooling efficiency.
3Power
If larger cooling packages are used to manage heat rejection, then cooling capacity increases, but physical footprint increases
Solution Approach 1:
The patent nests cooling system components within the existing enclosure space of the direct drive unit. Heat exchangers are mounted on internal enclosure surfaces, fan assemblies are positioned within the same volumetric space, and airflow paths utilize the existing enclosure geometry. This nesting approach allows the cooling package to be contained within the footprint of the direct drive unit itself, providing increased cooling capacity without increasing external dimensions.
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
Enhances cooling efficiency by effectively managing heat rejection, reducing energy loss, and minimizing the physical footprint of cooling systems while maintaining desired temperature levels.
Implementation Method 1
one or more heat exchanger assemblies connected to the enclosure body for cooling a process fluid associated with one or more of the DDU and the fluid pump
Implementation Method 2
one or more intake fan assemblies positioned in fluid communication with an external environment surrounding the enclosure body... draw air into the enclosure space from the external environment at the one or more intake fan assemblies and along an airflow path through the enclosure space
Implementation Method 3
one or more radiator assemblies may further be included in the one or more heat exchanger assemblies for receiving the process fluid, and positioned adjacent the one or more intake fan assemblies in the airflow path through the enclosure space to cool the process fluid with air from the external environment
Data Source
AI summary
Embodiments of an enclosure assembly to enhance cooling of a hydraulic fracturing direct drive unit (DDU) during operation are included. The enclosure assembly may include an enclosure body extending at least partially around an enclosure space to house the DDU for driving a fluid pump. The enclosure assembly may include one or more heat exchanger assemblies connected to the enclosure body for cooling a process fluid associated with one or more of the DDU and the fluid pump, and which may be configured to draw air into the enclosure space from and external environment, toward one or more radiator assemblies to cool the process fluid, and along an airflow path through the enclosure space. One or more outlet fan assemblies may be operative to discharge air from the enclosure space to the external environment to maintain a desired temperature of the enclosure space.