Electric Hydraulic Fracking Pumping With Single-VFD Powertrain

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional hydraulic fracking systems rely on diesel engines, leading to increased costs, noise, and environmental concerns due to the need for multiple diesel engines, transmissions, and trailers, which also result in parasitic losses and reduced productivity.

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, including gas turbine engines or an electric utility grid, to reduce the number of power sources and increase efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple diesel engines and transmissions are used to drive hydraulic pumps, then the required horsepower is achieved, but the device complexity and quantity of assets increase

Engineering Contradiction:

ImprovehorsepowerVSAvoiddevice complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent consolidates multiple diesel engines and transmissions into a single electric motor that drives multiple hydraulic pumps through a common power source, reducing the number of separate assets while maintaining required horsepower output

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A single electric motor serves multiple functions by driving several hydraulic pumps simultaneously, replacing the need for individual engine-transmission-pump combinations for each pump

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If the power rating of hydraulic pumps is increased, then the productivity improves, but the power rating of diesel engines and transmissions must also increase

Engineering Contradiction:

ImproveproductivityVSAvoidpower rating

Core Design Contradiction:

ProductivityVSPower

Solution Approach 1:

The patent replaces the mechanical diesel engine-transmission system with an electric motor system that can deliver higher power ratings more efficiently, enabling increased pump productivity without the same constraints on power scaling

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Power

If the number of diesel engines, transmissions, and hydraulic pumps increases, then the required horsepower is met, but the quantity of trailers and manpower required increases

Engineering Contradiction:

ImprovehorsepowerVSAvoidquantity of assets

Core Design Contradiction:

PowerVSQuantity of substance

Solution Approach 1:

Multiple pumps and their associated power sources are merged into a single integrated electric-driven system, reducing the total number of trailers and assets needed at the fracking site while maintaining required horsepower

Inventive Principle:

Principle #5Merging (Combining)

4Power

If diesel engines drive hydraulic pumps, then the pumps are powered, but parasitic losses occur that decrease available horsepower

Engineering Contradiction:

Improveavailable horsepowerVSAvoidparasitic losses

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent replaces the diesel engine mechanical drive system with an electric motor system that has fewer parasitic losses, thereby increasing the available horsepower to the hydraulic pumps

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent removes the intermediate transmission and mechanical coupling components that cause parasitic losses, directly coupling the electric motor to the pumps to eliminate energy waste

Inventive Principle:

Principle #2Taking out (Extraction)

5Ease of operation

If multiple trailers are used to transport and position configurations, then the assets are transported, but the operational cost and complexity increase

Engineering Contradiction:

Improveease of operationVSAvoidquantity of trailers

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

Multiple separate trailer-based configurations are merged into a single integrated trailer system that houses the electric motor and multiple pumps, reducing the number of trailers needed for transport and deployment

Inventive Principle:

Principle #5Merging (Combining)

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, reduces parasitic losses, lowers noise levels, and enhances productivity by providing continuous power to hydraulic pumps, thereby reducing 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

Methodology Applied

Scientific EffectVariable Frequency Drive:

Data Source

PatentUS11788396B2Electric driven hydraulic fracking system

Publication Date: 2023.10.17 HALLIBURTON ENERGY SERVICES INC

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. The single VFD converts the electric power of at least 13.8 kV to a VFD rated voltage level of at least 4160V and drives the single shaft electric motor at the VFD voltage level of up to 4160V to control the operation of the single shaft electric motor and the single hydraulic pump. The single shaft electric motor drives the single hydraulic pump with the rotation at the rated RPM level of at least 750 RPM. The single hydraulic pump continuously pumps the fracking media into the well at the HP level of at least 5000 HP. The single hydraulic pump operates on a continuous duty cycle to continuously pump the fracking media at the HP level of at least 5000 HP.