Mobile VFD Cabin Layout for Electric Hydraulic Fracking

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Solution Overview

Problem

Conventional hydraulic fracking systems rely on diesel engines, leading to increased costs, inefficiencies, and environmental concerns due to the need for multiple diesel engines, transmissions, and trailers, as well as parasitic losses and noise pollution.

Innovation Solution

The implementation of an electrically-driven hydraulic fracking system utilizing a variable frequency drive (VFD) cabin and mobile trailer, which consolidates power generation using gas turbine engines and distributes electric power to multiple pump configurations via medium-voltage cables, eliminating the need for diesel engines and reducing asset count and noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple diesel engines and transmissions are used to drive hydraulic pumps, then the required horsepower is achieved, but the operational cost and device complexity increase significantly

Engineering Contradiction:

ImprovehorsepowerVSAvoidnumber of diesel engines and transmissions

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent consolidates multiple diesel engines and transmissions into a single electric motor that drives all hydraulic pumps through a common electric power source, reducing the number of power generation units from multiple diesel engines to one electric motor while maintaining the required total horsepower output

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electric motor serves as a universal power source that can drive multiple hydraulic pumps simultaneously, replacing the dedicated one-to-one pairing of diesel engines with individual pumps, thereby achieving multi-functionality with a single power unit

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Power

If multiple diesel engines are deployed to increase horsepower capacity, then pumping capacity is enhanced, but parasitic losses increase and efficiency decreases

Engineering Contradiction:

Improvepumping capacityVSAvoidparasitic losses

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent replaces the mechanical diesel engine transmission system with an electric motor system that directly drives the hydraulic pumps, eliminating the mechanical parasitic losses associated with diesel engine transmissions and improving overall energy efficiency while maintaining pumping capacity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Power

If the number of hydraulic pumps is increased to achieve required horsepower, then power output is sufficient, but the quantity of trailers and manpower required increases

Engineering Contradiction:

Improverequired horsepowerVSAvoidnumber of trailers and equipment

Core Design Contradiction:

PowerVSQuantity of substance

Solution Approach 1:

The patent merges multiple hydraulic pump units onto a single trailer platform, driven by one electric motor, thereby consolidating the equipment quantity from multiple separate trailer units to one integrated trailer while achieving the required total horsepower through the combined output of multiple pumps

Inventive Principle:

Principle #5Merging (Combining)

4Power

If diesel engines are used to drive hydraulic pumps, then power is provided, but noise levels significantly increase

Engineering Contradiction:

Improvepower outputVSAvoidnoise pollution

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The patent substitutes diesel engines with an electric motor system that provides the same power output but generates significantly less noise, replacing the noisy combustion engine mechanism with a quieter electric drive system while maintaining the required horsepower for hydraulic pump operation

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 significantly reduces operational costs, increases efficiency by minimizing parasitic losses, and decreases noise pollution, while maintaining or enhancing the hydraulic pumping capacity, thus improving the overall fracking operation.

Implementation Method 1

the ventilation system is configured to generate an overpressure condition within the cabin to discourage the entry of dust and debris into the cabin

Methodology Applied

Scientific EffectOverpressure condition: Pressure Gradient

Implementation Method 2

one or more components of the medium-voltage VFD are coupled to the floor of the cabin via a vibration damping system

Methodology Applied

Scientific EffectVibration damping: Damping

Data Source

PatentUS11976525B2Electric driven hydraulic fracking operation

Publication Date: 2024.05.07 HALLIBURTON ENERGY SERVICES INC

AI summary

Certain embodiments of the present application relate to a variable frequency drive (VFD) cabin for a pump configuration including a mobile trailer on which the VFD cabin is to be mounted. The VFD cabin generally includes a medium-voltage VFD and a ventilation system. In certain embodiments, the ventilation system is configured to generate an overpressure condition within the cabin to discourage the entry of dust and debris into the cabin. In certain embodiments, one or more components of the medium-voltage VFD are coupled to the floor of the cabin via a vibration damping system. In certain embodiments, the VFD cabin may be directly coupled to a chassis of the mobile trailer without an intervening suspension being provided between the VFD cabin and the chassis.