Mobile VFD Cabin Layout for Electric Hydraulic Fracking Pumps
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Solution Overview
Problem
Conventional diesel-powered hydraulic fracking systems require multiple diesel engines and transmissions, leading to increased costs, parasitic losses, noise, and inefficiencies, necessitating a more efficient and cost-effective power solution.
Innovation Solution
A variable frequency drive (VFD) cabin mounted on a mobile trailer, incorporating a medium-voltage VFD and ventilation system, directly coupled to the trailer chassis, which powers hydraulic pumps using electric power generated by gas turbine engines, eliminating the need for diesel engines and reducing the number of power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple diesel engines and transmissions are used to power hydraulic pumps, then the required horsepower is achieved, but the cost, parasitic losses, and noise significantly increase
Solution Approach 1:
The patent combines multiple diesel engines into a single electric power source (generator) that powers all hydraulic pumps through a centralized electrical system, eliminating the need for each pump to have its own dedicated diesel engine and transmission
Solution Approach 2:
The patent replaces the mechanical connection between diesel engines and hydraulic pumps with an electrical power transmission system, where electric motors driven by a generator replace the direct mechanical coupling of diesel engines to pumps
2Power
If multiple diesel engines and transmissions are used, then the required power is achieved, but the number of trailers and personnel required increases
Solution Approach 1:
The patent consolidates multiple power sources into a single mobile power unit containing the generator and electrical control systems, which can be transported on one or fewer trailers compared to the multiple trailers needed for multiple diesel engine assemblies
Solution Approach 2:
The single electric power source serves multiple functions by powering all hydraulic pumps simultaneously, replacing the need for multiple dedicated power sources each requiring separate transport and setup
3Power
If multiple diesel engines are used to drive hydraulic pumps, then the required power is achieved, but the operational costs and setup time significantly increase
Solution Approach 1:
The patent replaces the complex mechanical transmission systems with electrical power transmission, which is more efficient and requires less maintenance, thereby improving operational efficiency
Solution Approach 2:
The electrical system allows for easier startup and operation with reduced manual intervention compared to multiple diesel engines requiring individual startup procedures and mechanical linkages
4Power
If diesel engines are used to power hydraulic pumps, then the required power is achieved, but noise levels significantly increase
Solution Approach 1:
The patent replaces diesel engines with electric motors powered by a generator, eliminating the combustion noise associated with internal combustion engines and significantly reducing overall noise levels at the fracking site
Data Source
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.