Modular Trailer Power System for Fracking Footprint Reduction
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Solution Overview
Problem
Current hydraulic fracturing operations rely on large diesel-powered pumps that require significant electrical power, necessitating large trailers for power generation, which creates a large footprint and logistical challenges, especially in restricted spaces.
Innovation Solution
A portable power generation system comprising a turbine generator on a trailer that produces AC power, connected to a rectifier assembly and inverter units on separate trailers, enabling efficient power distribution to drive well service pumps, reducing the overall footprint and allowing for independent operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large diesel-powered pumps are used for hydraulic fracturing, then sufficient pumping power is achieved, but the electrical power generation system requires large trailers creating a large footprint
Solution Approach 1:
The power generation system is divided into multiple independent modular units (rectifier assembly, inverter units, turbine generator) that can be distributed across multiple trailers. Each module operates independently but contributes to the overall power output, allowing the system to achieve high pumping power while distributing the physical footprint across several smaller trailers rather than one large trailer.
Solution Approach 2:
The system transitions from a single large centralized power generation trailer to a distributed multi-trailer configuration. By organizing power generation components across multiple trailers in a networked arrangement, the system effectively changes the spatial dimension from one large footprint to multiple smaller footprints, reducing the area required at any single location while maintaining total power output.
2Power
If large trailers are used for power generation, then sufficient electrical power is available, but logistical challenges increase especially in restricted spaces
Solution Approach 1:
The power generation system is segmented into multiple smaller modular units that can be transported and positioned independently using standard towing equipment. This segmentation eliminates the need for specialized heavy-duty transport required for single large trailers, significantly improving ease of operation and deployment in restricted spaces while collectively providing the required electrical power.
Solution Approach 2:
The system employs a dynamic modular configuration where trailers can be added or removed from the power generation network based on instantaneous power requirements. This flexibility allows the system to adapt to changing operational demands and site constraints, improving logistical ease by enabling incremental deployment and reconfiguration without moving entire large trailer assemblies.
3Power
If integrated power networks are used to supply electrical power to pump motors, then power distribution is achieved, but the system complexity increases
Solution Approach 1:
Each modular unit in the power generation system is designed with universal functionality to perform multiple roles: the turbine generator can serve as both prime mover and electrical generator, the rectifier assembly can handle both AC-to-DC conversion and power regulation, and the inverter units can perform DC-to-AC conversion and power distribution. This multi-functionality reduces the need for specialized dedicated components, simplifying the overall system architecture while maintaining effective power distribution capability.
Solution Approach 2:
The modular power generation system incorporates self-regulating control mechanisms where each unit autonomously manages its own operation and can independently adjust to maintain system stability. The units self-coordinate to balance power generation and distribution without requiring complex centralized control systems, thereby reducing overall system complexity while ensuring reliable power distribution to pump motors.
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 self-contained, efficient power solution that reduces the physical footprint and allows for easy transportation and deployment, enabling hydraulic fracturing operations in restricted spaces while maintaining reliability and efficiency.
Implementation Method 1
a turbine generator, mounted on a first trailer, operable to generate AC electrical power
Implementation Method 2
a rectifier assembly operable to generate DC electrical power
Implementation Method 3
at least one inverter unit, mounted on a second trailer, electrically coupled to the rectifier assembly, where the at least one inverter unit is operable to generate AC electrical power
Data Source
AI summary
A power system for use in hydraulic fracturing or fracking of wells is disclosed. The power system is generally self-contained on a transportable system, such as a trailer. The weight and configuration of the trailer must be sized to be hauled legally on United States roadways. The system components include a turbine generator, rectifier, inverter units and AC motors.