Power Distribution Trailer for Electric Fracking Pump Control
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Solution Overview
Problem
Conventional hydraulic fracking systems rely on multiple diesel engines, leading to increased costs, noise, and environmental issues due to parasitic losses, noise pollution, and the need for extensive manpower and equipment, which complicates operations and increases expenses.
Innovation Solution
Implementing an electric-driven hydraulic fracking system with a single Variable Frequency Drive (VFD), a single shaft electric motor, and a 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 the required horsepower is achieved, but the cost, noise levels, and operational complexity increase significantly
Solution Approach 1:
The patent consolidates multiple diesel engines and hydraulic pumps into a single integrated electric-driven system. A single electric motor replaces multiple diesel engines, and multiple hydraulic pumps are driven by this single motor through a common drive shaft, thereby reducing operational complexity while maintaining the required total horsepower output.
Solution Approach 2:
The single electric motor serves multiple functions by driving all hydraulic pumps simultaneously through a universal drive shaft mechanism. This multi-functional approach eliminates the need for separate engines for each pump, reducing the number of components and simplifying operations while delivering the cumulative power needed for the fracking operation.
2Power
If multiple diesel engines and hydraulic pumps are deployed, then the required power is achieved, but the number of trailers and transportation requirements increase
Solution Approach 1:
The invention merges multiple previously separate units (engines and pumps) into a single integrated trailer-mounted system. The electric motor, drive shaft, and multiple hydraulic pumps are combined into one cohesive unit that can be transported on a single trailer, eliminating the need for multiple separate trailers and reducing transportation logistics.
3Power
If diesel engines are used to drive hydraulic pumps, then power is delivered, but parasitic losses decrease the available horsepower
Solution Approach 1:
The patent replaces the diesel engine mechanical drive system with an electric-driven system. Electric motors eliminate the parasitic losses associated with diesel engine mechanical transmissions and auxiliary systems, delivering more of the generated power directly to the hydraulic pumps and increasing the available horsepower for the fracking operation.
4Power
If multiple diesel engines are operated, then the required power output is achieved, but noise levels and environmental impact increase
Solution Approach 1:
The invention substitutes diesel engines with electric motors to drive the hydraulic pumps. Electric motors operate significantly quieter than diesel engines and produce no exhaust emissions, thereby eliminating noise pollution and other harmful environmental factors while maintaining the required power output for the fracking operation.
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 continuously pumping fracking media, thereby lowering costs and environmental impact while maintaining high horsepower levels.
Implementation Method 1
a single Variable Frequency Drive (VFD), a single shaft electric motor
Implementation Method 2
a single shaft electric motor, and a single hydraulic pump positioned on a single pump trailer
Implementation Method 3
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.