Power Distribution Trailer Layout for Electric Fracking Pumps
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Solution Overview
Problem
Conventional hydraulic fracking systems rely on multiple diesel engines, leading to increased costs, complexity, and reduced efficiency due to parasitic losses, noise, and environmental concerns, as well as the need for numerous trailers and manpower.
Innovation Solution
Implementing an electric-driven hydraulic fracking system with a single Variable Frequency Drive (VFD), single shaft electric motor, and single hydraulic pump on a single trailer, powered by a consolidated power generation system, reducing the number of gas turbine engines and medium voltage cables, and utilizing a power distribution trailer to efficiently distribute electric power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple diesel engines are used to drive hydraulic pumps, then sufficient power is available to prepare the well, but the number of trailers, manpower, and operational complexity increases significantly
Solution Approach 1:
The patent consolidates multiple diesel engines and hydraulic pumps into a single integrated electric-driven hydraulic pump system. The electric motor provides sufficient horsepower to replace multiple diesel engines, while the single pump trailer configuration merges multiple separate trailers into one unified platform, thereby reducing operational complexity while maintaining required power output.
Solution Approach 2:
The electric-driven hydraulic pump system is designed to perform multiple functions that previously required separate diesel engines and pumps. The single electric motor can drive the hydraulic pump while also powering auxiliary systems, creating a multi-functional platform that reduces the overall number of equipment units needed at the fracking site.
2Power
If multiple diesel engines and hydraulic pumps are deployed, then sufficient power is achieved, but parasitic losses increase and reduce the effective horsepower available for hydraulic pumps
Solution Approach 1:
The patent extracts and eliminates the parasitic losses associated with multiple diesel engines by replacing them with a single electric motor system. The electric-driven system removes the unnecessary energy consumption from multiple separate power sources and their associated auxiliary systems, concentrating power delivery into a single efficient platform that minimizes wasted energy.
Solution Approach 2:
The patent replaces the mechanical diesel engine system with an electric-driven system. This substitution eliminates the parasitic losses inherent in diesel engine operation, including fuel consumption by auxiliary systems and mechanical inefficiencies, thereby increasing the effective horsepower available to the hydraulic pump.
3Power
If the number of hydraulic pumps is increased to achieve required horsepower, then sufficient power is available, but the number of trailers and CDL drivers required increases
Solution Approach 1:
The patent merges multiple separate hydraulic pump units into a single integrated electric-driven hydraulic pump system. By consolidating the power source and pump functions onto one trailer platform, the system delivers the required total horsepower without requiring multiple separate trailers, thereby reducing the quantity of equipment units needed.
4Power
If multiple diesel engines are used, then sufficient power is available, but noise levels and environmental impact increase
Solution Approach 1:
The patent replaces the mechanical diesel engine system with an electric-driven system. This substitution significantly reduces noise levels as electric motors operate much quieter than diesel engines. The electric-driven hydraulic pump system maintains sufficient horsepower while eliminating the harmful noise and environmental factors associated with multiple diesel engines.
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 decreases the asset count, minimizes parasitic losses, reduces noise levels, and enhances operational efficiency by allowing continuous duty cycles for hydraulic pumps, thereby lowering operational costs and environmental impact.
Implementation Method 1
a single Variable Frequency Drive (VFD), a single shaft electric motor, and a single hydraulic pump positioned on a single pump trailer
Data Source
AI summary
An electric driven hydraulic fracking system is disclosed. A pump configuration that includes the single VFD, the single shaft electric motor, and the single hydraulic pump that is mounted on the single pump trailer. A power distribution trailer distributes the electric power generated by the power generation system at the power generation voltage level to the single VFD and converts the electric power at a power generation voltage level to a VFD voltage level and controls the operation of the single shaft electric motor and the single hydraulic pump. The power distribution trailer converts the electric power generated by the power generation system at the power generation level to an auxiliary voltage level that is less than the power generation voltage level. The power distribution trailer distributes the electric power at the auxiliary voltage level to the single VFD that controls an operation of the of the auxiliary systems.