Signal Assembly Visual Indicators Hydraulic Fracturing Pumps
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Solution Overview
Problem
Hydraulic fracturing systems face challenges with the safety of personnel due to potential failures in pressurized fluid lines, which can cause personal injury, and existing systems lack effective visual indicators for operational states, making it difficult to assess safety conditions during maintenance or operation.
Innovation Solution
An electrical hydraulic fracturing system with a signal assembly that uses differently colored lights to indicate operational states, including power availability and fluid pressure levels, allowing personnel to safely navigate potentially hazardous zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high pressure pumps are used to generate fracturing pressures, then the required pressure for hydraulic fracturing is achieved, but the pumps and associated engines have substantial volume and mass requiring heavy duty trailers for transport
Solution Approach 1:
The patent replaces traditional diesel engines and mechanical transmissions with electric motors controlled by variable frequency drives. This substitution reduces the mechanical complexity and mass of the power generation system while maintaining the ability to generate high fracturing pressures, thereby reducing the weight and transport requirements of the pump system
2Object-affected harmful factors
If diesel engines and transmission are replaced with electrical motors, then noise, emissions, and vibrations are reduced, but the system requires new infrastructure for electrical power delivery
Solution Approach 1:
The patent integrates multiple functions into the electrical system: variable frequency drives not only control motor speed but also perform diagnostics and provide communication interfaces. The electrical infrastructure serves both power delivery and control/monitoring functions, reducing the need for separate systems and mitigating the complexity increase
3Object-affected harmful factors
If discharge iron zones are restricted to avoid personal injury, then safety of personnel is improved, but maintenance or inspection requires entry into these hazardous zones
Solution Approach 1:
The patent implements a monitoring system with sensors that detect pressure, flow, and operational parameters in real-time. This feedback is transmitted to remote locations, allowing operators to monitor hazardous zones without physical presence. The system provides continuous information about the state of discharge iron and associated hazards, enabling safe remote operation and reducing the need for personnel entry into dangerous areas
4Loss of information
If visual indicators for operational states are added to the system, then safety assessment is improved, but device complexity increases
Solution Approach 1:
The patent uses color-coded visual indicators (such as colored lights or displays) to represent different operational states of the system. Each color corresponds to a specific state (e.g., green for normal operation, yellow for warning, red for hazard), providing immediate and intuitive information about system status without requiring complex displays or interfaces, thereby minimizing the increase in device complexity
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 enhances safety by providing clear visual signals for operational states, enabling personnel to avoid hazardous conditions and preventing injuries from unexpected pressurized fluid line failures.
Implementation Method 1
Each of the light assemblies selectively emit visual light of a color different from visual light emitted by other light assemblies
Data Source
AI summary
A hydraulic fracturing system includes an electrically powered pump that pressurizes fluid, which is piped into a wellbore to fracture a subterranean formation. System components include a fluid source, an additive source, a hydration unit, a blending unit, a proppant source, a fracturing pump, and an electrically powered motor for driving the pump. Also included with the system is a signal assembly that visually displays operational states of the pump and motor, thereby indicating if fluid discharge lines from the pump contain pressurized fluid. The visual display of the signal assembly also can indicate if the motor is energized, so that the discharge lines might soon contain pressurized fluid.