Portable Power System Integrating Hydraulic, Electric, and Pneumatic Outputs
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Solution Overview
Problem
Hydraulic fracturing operations require extensive infrastructure, leading to increased operational costs, safety concerns, and environmental impact due to the large number of vehicles, equipment, and personnel needed at well sites, along with inefficiencies in equipment maintenance and fuel consumption.
Innovation Solution
A portable power system that integrates a primary power source to provide hydraulic, pneumatic, and electric power, reducing the need for multiple vehicles and personnel by using a single platform with a hydraulic power supply system, electric power supply system, and pneumatic power supply system, which can power frac pumps, tools, and site equipment, and includes SMART technology for remote monitoring and diagnostics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple transportable pumping units with separate engines and tractors are used, then sufficient hydraulic power is provided for fracturing operations, but the number of vehicles, personnel, and operational infrastructure increases significantly
Solution Approach 1:
The patent combines multiple separate power sources (engines and tractors) into a single integrated power unit that provides hydraulic power to multiple fracturing pumps. This consolidation reduces the number of vehicles and equipment needed at the well site while maintaining sufficient total hydraulic power output.
Solution Approach 2:
The single power unit is designed to perform multiple functions simultaneously - powering multiple hydraulic fracturing pumps, providing electrical power through an integrated generator, and operating pneumatic tools. This multi-functionality eliminates the need for separate dedicated power sources for each function.
2Ease of operation
If multiple tractors with drivers are deployed, then each pumping unit can be operated and moved, but operational costs and safety risks increase due to more personnel on site
Solution Approach 1:
The integrated power unit is designed to operate autonomously with reduced human intervention. The single power unit can service multiple pumps simultaneously, and the system includes automated controls and monitoring that reduce the need for operators to physically move between equipment, thereby reducing personnel requirements while maintaining operational capability.
3Reliability
If extensive operational infrastructure is established, then fracturing operations can be supported, but capital expenditures and operating costs increase
Solution Approach 1:
The patent merges multiple separate infrastructure components (fuel storage for multiple engines, maintenance facilities for multiple vehicles, operator cabins for multiple tractors) into a single integrated infrastructure support system for the unified power unit. This consolidation maintains all necessary operational support functions while significantly reducing the total infrastructure footprint and associated costs.
4Productivity
If multiple separate power sources are used, then each unit can operate independently, but fuel consumption and maintenance requirements increase
Solution Approach 1:
The single power unit is designed with universal power output capabilities that can independently service multiple hydraulic pumps, electrical loads, and pneumatic tools simultaneously. The unified power source optimizes fuel consumption by coordinating power delivery across all functions, eliminating the redundant fuel consumption that would occur with multiple separate engines running simultaneously.
Data Source
AI summary
The application is directed to a power system that may be provided in a portable form and operationally configured for use at a work site as a single source of electric power, hydraulic power and pneumatic power for work site operations. In regard to hydraulic fracturing stimulation of a wellbore, the power system is operationally configured as the source of hydraulic power for transportable pumping units of a fracturing operation and for hydraulic power tools, as the source of pneumatic power for pneumatic power tools and as the source of electric power for electric power tools and electronic equipment at a well site.