Modular Switchgear for Electric Fracturing Pumps
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Solution Overview
Problem
Hydraulic fracturing operations rely on diesel-generated mechanical power, which is costly, environmentally unfriendly, and logistically challenging, with turbine power generation inefficient at fluctuating loads common in fracturing operations, leading to congestion and safety issues at well sites.
Innovation Solution
A modular switchgear system and power distribution system using electric-powered fracturing pumps with variable frequency drives, transformers, and a cooling system mounted on trailers, enabling efficient and safe power management with reduced equipment congestion and improved safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If diesel-generated mechanical power is used, then sufficient power is available for fracturing operations, but cost increases, environmental harm worsens, and logistical complexity increases
Solution Approach 1:
The patent replaces diesel-generated mechanical power with electric power. Electric motors driven by turbine generators substitute for diesel engines, eliminating the combustion process and associated environmental harm while providing sufficient power for fracturing operations. The electric motor directly couples to the pump without mechanical transmission components.
2Object-affected harmful factors
If turbine power generation is used, then environmental friendliness improves and operational cost decreases, but efficiency drops under fluctuating loads
Solution Approach 1:
The patent incorporates variable frequency drives (VFDs) that dynamically adjust the operating speed of electric motors to match the instantaneous power demands of fracturing pumps. This allows the turbine generator to operate more consistently at optimal efficiency points while the VFD handles load fluctuations, resolving the contradiction between environmental friendliness and energy efficiency under varying loads.
3Ease of operation
If numerous cables and hoses are extended across the well site, then power and fluid can be delivered to equipment, but traffic congestion increases and safety risks worsen
Solution Approach 1:
The patent integrates the power distribution system with the fluid delivery system by mounting the electric motor directly on the pump assembly. This consolidation eliminates separate power cables and fluid hoses, reducing the number of extended connections across the well site while maintaining full equipment connectivity and reducing safety risks.
4Adaptability or versatility
If operators connect and disconnect numerous hoses and cables, then equipment can be configured for different operations, but operational complexity and confusion increase
Solution Approach 1:
The patent combines power and fluid connections into a single integrated pump assembly with the electric motor mounted directly on it. This merger reduces the number of separate connections operators must manage while maintaining the ability to configure equipment for different operations, thereby improving operational simplicity without sacrificing adaptability.
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 a safer, more cost-effective, and environmentally friendly power solution for hydraulic fracturing, reducing logistical challenges and environmental impact by using electric power with efficient load management and simplified equipment layout.
Implementation Method 1
a transformer distributing power to the electric pump, the power being received from at least one generator at a voltage higher than an operating voltage of the electric pump
Implementation Method 2
a liquid cooling system, such as a radiator, is provided for cooling one or more variable frequency drives (VFDs)
Data Source
AI summary
A hydraulic fracturing system for fracturing a subterranean formation includes a support structure that includes an electric powered pump, arranged in a first area, the electric powered pump powered by at least one electric motor, also arranged in the first area. The system further includes a variable frequency drive (VFD), arranged in a second area proximate the first area, connected to the at least one electric motor to control the speed of the at least one electric motor. The system includes a transformer, arranged in a third area proximate the second area. The system also includes a cooling system, arranged in a fourth area proximate the third area, the cooling system providing a cooling fluid to the VFD via one or more headers.