Modular Pump Skid Hydraulic Fracturing Redundancy
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Solution Overview
Problem
Conventional hydraulic fracturing systems face inefficiencies due to non-uniform connections that require extensive time and resources to set up, lack flexibility in pump configurations, and are prone to system-wide shutdowns if a single component fails, leading to increased costs and safety hazards.
Innovation Solution
The introduction of modular pump skids with standardized connections and closed-loop hydraulic pump circuits, allowing for independent operation of multiple pump circuits powered by a single prime mover, which redistributes unused horsepower to maintain operation even if one circuit fails, and reduces fluid usage and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional non-uniform connections are used in hydraulic fracturing systems, then system flexibility is reduced and installation time increases, but standardized modular connections could simplify setup and improve adaptability
Solution Approach 1:
The hydraulic fracturing system is divided into modular pump skid units, each with standardized connections. These self-contained modules can be independently configured and assembled, eliminating the need for complex custom fabrication and reducing on-site installation time while improving system flexibility and adaptability.
Solution Approach 2:
Standardized universal connections are implemented across all pump skid modules, allowing any module to be interchangeably connected to any other. This universal interface enables flexible system configurations without requiring custom connection designs, thereby reducing installation time and improving adaptability to different well requirements.
2Reliability
If a single component failure causes system-wide shutdown in conventional systems, then system reliability decreases, but modular independent circuits could maintain operation and improve safety
Solution Approach 1:
The hydraulic system is segmented into multiple independent closed-loop circuits, each capable of operating autonomously. This segmentation ensures that a failure in one circuit does not propagate to other circuits, maintaining system reliability and reducing safety hazards associated with system-wide shutdowns.
Solution Approach 2:
The modular independent circuit design provides built-in redundancy and fault isolation capabilities before failures occur. By designing the system with independent circuits from the outset, the system is prepared to withstand component failures without compromising overall operation or safety, effectively cushioning against potential harm.
3Reliability
If multiple pump circuits share a single prime mover, then horsepower can be redistributed to maintain operation during failures, but system complexity increases
Solution Approach 1:
The power transmission system is segmented into independent hydraulic circuits, each with its own pump assembly connected to the single prime mover. This segmentation allows the prime mover to redistribute horsepower to specific circuits as needed, maintaining continuous operation during failures while managing complexity through modular circuit design.
Solution Approach 2:
The system is designed to maintain continuous useful action through horsepower redistribution. When one circuit fails, the prime mover automatically redirects power to remaining operational circuits, ensuring uninterrupted hydraulic fracturing operations. This continuity is achieved through the modular independent circuit architecture that isolates failures while maintaining overall system functionality.
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 installation time, minimizes the need for non-uniform connections, enhances system reliability by allowing continued operation if one pump circuit fails, and optimizes fluid usage, leading to a more efficient and safer hydraulic fracturing process.
Implementation Method 1
each hydraulic pump circuit may include a hydraulic pump and a hydraulically driven pump fluidly coupled to the hydraulic pump
Data Source
AI summary
A modular pump skid includes a base, a prime mover mounted on the base, and one or more hydraulic pump circuits removably mounted on the base and operationally coupled to the prime mover, wherein each hydraulic pump circuit has a hydraulic pump operationally coupled to the prime mover and a hydraulically driven pump fluidly coupled to the hydraulic pump. Each hydraulic pump circuit is in a closed loop independent of other hydraulic pump circuits.