Mobile Substation Power Layout for Grid-Powered Fracturing Pumps

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Solution Overview

Problem

Existing hydraulic fracturing operations rely on diesel-powered equipment, which is costly, inefficient under prolonged overload, generates high noise levels, and requires expensive maintenance, limiting the efficiency and sustainability of fracturing processes.

Innovation Solution

A system utilizing electrical power from a utility electric grid to power equipment for delivering fracturing fluid to a wellbore, comprising a mobile substation with parallel transformer units, electric motors coupled to hydraulic fracturing pumps, and open air relay cables for power delivery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If diesel powered equipment is used to power hydraulic fracturing operations, then power can be provided on-site, but the running cost increases due to costly fuel prices

Engineering Contradiction:

Improveon-site power provisionVSAvoidrunning cost

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent replaces diesel-powered mechanical systems with electric motors powered by utility grid electricity. This substitution eliminates the need for costly diesel fuel while providing sufficient on-site power for hydraulic fracturing operations, directly resolving the contradiction between on-site power provision and running cost

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Power

If diesel powered equipment is used, then power can be delivered to pumps, but noise levels exceed 88 decibels limiting human exposure

Engineering Contradiction:

Improvepower delivery to pumpsVSAvoidnoise pollution

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The patent substitutes diesel engines with electric motors that deliver the same pumping power without generating excessive noise. This resolves the contradiction by maintaining power delivery capability while eliminating the harmful noise factor that limits human exposure

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If diesel powered equipment is used, then operations can proceed, but efficiency decreases under prolonged overload conditions

Engineering Contradiction:

Improveoperational continuityVSAvoidefficiency under overload

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces diesel engines with electric motors that maintain high efficiency under prolonged overload conditions. Electric motors can sustain overload operation without the efficiency degradation that plagues diesel engines, thus resolving the contradiction between operational continuity and reliability under stress

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Power

If diesel powered equipment is used, then power can be provided, but maintenance costs increase due to expensive maintenance charges

Engineering Contradiction:

Improvepower provisionVSAvoidmaintenance cost

Core Design Contradiction:

PowerVSEase of repair

Solution Approach 1:

The patent replaces diesel-powered equipment with electric motor systems that have fewer moving parts and lower maintenance requirements. This substitution maintains power provision capability while significantly reducing maintenance costs, resolving the contradiction between power provision and ease of repair

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

5Adaptability or versatility

If diesel powered equipment is used, then on-site power can be generated, but the equipment generates high noise levels

Engineering Contradiction:

Improveon-site power generation capabilityVSAvoidnoise generation

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The patent substitutes diesel generators with electric motors connected to utility grid power. This maintains the capability of providing on-site power for fracturing operations while eliminating the noise generation associated with diesel engines, resolving the contradiction between adaptability and harmful factor generation

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

This solution provides a cost-effective, efficient, and sustainable means of powering hydraulic fracturing operations, reducing noise pollution, and minimizing maintenance costs while ensuring reliable power delivery.

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

Implementation Method 2

a plurality of electric motors, each electric motor operatively coupled to at least one fracturing pump

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Data Source

PatentUS12206224B2Mobile substation system for fracturing operations

Publication Date: 2025.01.21 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 receiving 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.