Mobile Grid Substations for Electric Fracturing Power Delivery

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Solution Overview

Problem

Existing hydraulic fracturing operations rely on diesel-powered equipment or on-site generators, which are costly, inefficient under overload, noisy, and require frequent maintenance, limiting their effectiveness and safety.

Innovation Solution

A system utilizing power from a utility electric grid, comprising mobile substations, transformer units, switchgear, and open air relay cables to power hydraulic fracturing pumps, ensuring redundancy and efficient power delivery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If diesel powered equipment is used to supply power to electric motors and pumps, then power can be provided on-site, but the running cost increases due to costly fuel and frequent maintenance

Engineering Contradiction:

Improvepower supply reliabilityVSAvoidfuel cost

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The invention extracts the power source from the mobile fracturing equipment and connects directly to the utility electric grid, eliminating the need for diesel generators. This removes the fuel consumption and associated costs while maintaining reliable power supply through grid connection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system utilizes the existing utility electric grid infrastructure to power fracturing operations, allowing the same grid connection to serve multiple purposes including fracturing pumps, blending equipment, and other operational needs, thereby eliminating the need for dedicated on-site generation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Power

If diesel powered equipment is used, then power can be provided on-site, but noise levels exceed 88 decibels limiting human exposure

Engineering Contradiction:

Improvepower outputVSAvoidnoise level

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The invention removes the noisy diesel generator from the site and replaces it with electric motors powered by grid electricity. Electric motors operate significantly quieter than diesel engines, eliminating the harmful noise levels that exceed 88 decibels while maintaining the required power output for fracturing operations.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If diesel powered equipment is used, then power can be provided on-site, but the equipment is unable to operate efficiently under prolonged overload conditions

Engineering Contradiction:

Improveoperational efficiencyVSAvoidoverload performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention changes the power source from diesel generators to electric motors with variable frequency drives. This allows for precise control of motor speed and torque, enabling efficient operation under prolonged overload conditions by adjusting electrical parameters rather than relying on mechanical diesel engine performance.

Inventive Principle:

Principle #35Parameter changes

4Power

If diesel powered equipment is used, then power can be provided on-site, but expensive maintenance charges are required

Engineering Contradiction:

Improvepower supplyVSAvoidmaintenance cost

Core Design Contradiction:

PowerVSEase of repair

Solution Approach 1:

The invention replaces the mechanical diesel generator system with an electrical motor system powered by the utility grid. Electric motors have fewer moving parts, no combustion engine maintenance requirements, and significantly lower maintenance costs compared to diesel generators, while providing reliable power supply.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system provides reliable, cost-effective, and efficient power for hydraulic fracturing operations, reducing noise and maintenance needs while meeting regulatory standards.

Implementation Method 1

operating at least two transformer units in parallel to receive power from a utility electric grid and step down the line voltage of the power from the utility electric grid

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250379426A1Method for accessing electric grids to power fracturing operations

Publication Date: 2025.12.11 TYPHON TECH SOLUTIONS (U S) LLC

AI summary

A method and system are disclosed for providing electrical power from a utility electric grid to a fracturing operation, and an electrically powered fracturing system. A mobile substation includes at least two transformer units that are operatively coupled to the utility electric grid in a parallel orientation, wherein the transformer units are capable of accessing power from the utility electric grid and stepping down the power for delivery to a switchgear. An electric motor is operatively coupled to a hydraulic fracturing pump and operatively controlled by a variable frequency drive. At least one open air relay cable is operatively coupled between the switchgear and the electric motor and capable of delivering power to the electric motor.