Removable Pump Modules for Faster Wellsite Pump Replacement
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Solution Overview
Problem
Conventional pumping units for wellbore operations, such as hydraulic fracking, are not modularized, leading to time-consuming pump replacements and transportation challenges due to their weight and lack of modularity.
Innovation Solution
A modularized electric pumping unit with removable pump modules, comprising a base structure and detachable pump modules that include a pump, driveline, and auxiliary systems, allowing for efficient assembly and disassembly for transportation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional non-modularized pumping units are used, then complete pumping units must be maintained as back-ups, but this leads to time-consuming pump replacements and transportation challenges due to weight
Solution Approach 1:
The pumping unit is divided into modular components: a base structure containing the electric motor and control systems, and detachable pump modules that can be independently removed and replaced. This segmentation enables rapid pump replacement without requiring replacement of the entire pumping unit, directly addressing the productivity issue while managing complexity through standardized interfaces.
2Ease of operation
If complete pumping units are maintained as back-ups, then pump replacement is faster, but transportation becomes challenging due to weight restrictions
Solution Approach 1:
By segmenting the pumping unit into a heavy base structure and lighter pump modules, the system allows transportation of only the necessary pump modules rather than the complete pumping unit. The base structure remains stationary at the well site, while individual pump modules can be easily transported and swapped as needed.
Solution Approach 2:
The pump modules are extracted as separate, removable components from the base structure. This extraction allows the pump modules to be independently transported, stored, and replaced without moving the entire pumping unit, thereby reducing transportation weight while maintaining operational efficiency.
3Ease of manufacture
If conventional pumping units are used, then transportation is simplified, but pump replacement becomes time-consuming and capital requirements increase
Solution Approach 1:
The modular design with detachable pump modules enables rapid maintenance operations. When a pump module requires maintenance or replacement, it can be quickly disconnected from the base structure and swapped with a pre-prepared module, dramatically reducing downtime compared to conventional units that require complete unit replacement or extensive on-site repairs.
Solution Approach 2:
Multiple pump modules can be pre-assembled and prepared in advance at a centralized location. When a field pump module needs replacement, a ready-to-install module is already available, eliminating the need for time-consuming on-site assembly or repair operations.
Data Source
AI summary
A modularized, electric pumping unit comprising: a base structure; an electric motor mounted on the base structure; and one or more pump modules. Each of the one or more pump modules includes a pump and a pump module structure, and can further include a pump auxiliary system comprising an oil lubrication pump, an oil reservoir, one or more oil filters, an oil cooler, a sensor package, a speed reducer, or a combination thereof. The one or more pump modules are configured to be removably mounted on the base structure and driven by the electric motor.