Integrated Switchgear Trailer Layout to Eliminate Frac Cables
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Solution Overview
Problem
Existing hydraulic fracturing equipment trailers face design constraints due to road regulations, leading to undesirable compromises in compactness and redundancy, which increase costs, complexity, and safety risks.
Innovation Solution
A consolidated switchgear system is integrated into a single oversized trailer, incorporating remote monitoring and control features, reducing redundant components, and eliminating interconnecting cables, with load-sharing capabilities to simplify operations and enhance safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple independent switchgear trailers are used to comply with professional codes, then reliability and code compliance are improved, but device complexity and cost increase due to redundant breakers and interconnecting cables
Solution Approach 1:
The patent consolidates multiple switchgear trailers into a single integrated switchgear unit that combines common bus and distribution switchgear functions. This merging eliminates redundant incoming and outgoing breakers across multiple trailers, reducing device complexity while maintaining code compliance through integrated protective devices and unified system architecture.
Solution Approach 2:
The integrated switchgear unit performs multiple functions that previously required separate trailers: it provides common bus functionality, distribution switchgear capabilities, and protective relaying in a single multi-functional device. This universal design reduces the number of components needed while maintaining all necessary code-compliant functions.
2Ease of operation
If smaller compact trailers are used to comply with road regulations, then mobility and ease of transport are improved, but design flexibility and functionality are compromised
Solution Approach 1:
By combining common bus switchgear and distribution switchgear into a single integrated unit, the patent reduces the overall footprint and weight of the switchgear system. This consolidation enables the system to be transported on smaller, more mobile trailers that comply with road regulations, while the integrated design maintains full functionality and adaptability for various well site configurations.
3Reliability
If redundant switchgear breakers are used across multiple trailers, then reliability and code compliance are improved, but cost and device complexity increase
Solution Approach 1:
The patent integrates common bus and distribution switchgear into a single unit with shared protective devices. Instead of having separate incoming and outgoing breakers in multiple independent trailers, the integrated system uses unified breakers that provide protective coverage for all circuits, reducing the total number of breakers while maintaining equivalent or improved reliability through coordinated protection schemes.
Solution Approach 2:
The integrated switchgear design uses multi-functional breakers and protective relays that can protect multiple circuits and functions simultaneously. This universal protective approach reduces the quantity of breakers needed compared to traditional multi-trailer configurations, while maintaining comprehensive protective coverage for all equipment.
4Reliability
If interconnecting cables are used between multiple switchgear trailers, then system functionality is maintained, but cost and installation complexity increase
Solution Approach 1:
By consolidating common bus and distribution switchgear into a single integrated unit, the patent eliminates the need for interconnecting cables between multiple trailers. The integrated design provides direct internal connections between bus and distribution circuits, removing cable-related complexity and cost while maintaining full system connectivity and functionality through internal buswork and integrated circuitry.
Data Source
AI summary
A hydraulic fracturing system for fracturing a subterranean formation includes a primary switchgear arranged on a support structure. The system also includes a secondary switchgear, arranged on the support structure, the secondary switchgear positioned separately from the primary switchgear and within an enclosure, the secondary switchgear receiving an electrical input from the primary switchgear and including an plurality of feed connections for supplying electrical power to a plurality of fracturing equipment.