Single-VFD Fracking Pump Layout to Cut Parasitic Losses
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Solution Overview
Problem
Conventional hydraulic fracking systems rely on diesel engines, leading to increased costs, noise pollution, and inefficiencies due to the need for multiple engines, transmissions, and trailers, which also result in parasitic losses and extended operation durations.
Innovation Solution
Implementing an electric-driven hydraulic fracking system utilizing a single Variable Frequency Drive (VFD), a single shaft electric motor, and a single hydraulic pump on a single trailer, powered by a consolidated electric power generation system, reducing the number of power sources and cabling required, and incorporating redundancy for continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple diesel engines and transmissions are used to drive multiple hydraulic pumps, then the required horsepower for hydraulic pumps can be achieved, but the operational cost and complexity significantly increase
Solution Approach 1:
The patent consolidates multiple diesel engines, transmissions, and hydraulic pumps into a single integrated electric motor-driven hydraulic pump system. This merging eliminates the need for multiple separate power sources and transmission systems, reducing overall system complexity while maintaining the required horsepower output for hydraulic fracking operations.
Solution Approach 2:
The single electric motor is designed to perform multiple functions that previously required separate diesel engines and transmissions. The electric motor directly drives the hydraulic pump without intermediate transmission components, creating a universal power source that replaces multiple specialized components and reduces system complexity.
2Quantity of substance
If the power rating of hydraulic pumps is increased to reduce the quantity of pumps, then the power rating of diesel engines must also increase, requiring more trailers and increasing operational costs
Solution Approach 1:
The patent replaces the mechanical diesel engine-transmission system with an electric motor system. This substitution allows for more efficient power transmission directly to the hydraulic pump, eliminating parasitic losses associated with diesel engines and transmissions. The electric motor can deliver full power rating to the pump without the efficiency penalties of mechanical transmission systems.
3Power
If multiple diesel engines are positioned at the fracking site, then the required horsepower can be provided, but the noise levels significantly increase
Solution Approach 1:
The patent substitutes diesel engines with an electric motor system, replacing combustion-based power generation with electric power. This substitution eliminates the noise generated by diesel engine combustion, exhaust systems, and mechanical transmissions, significantly reducing noise levels at the fracking site while maintaining the required horsepower output.
4Power
If diesel engines drive hydraulic pumps, then power can be transmitted, but parasitic losses occur that decrease the available horsepower
Solution Approach 1:
The patent extracts and removes the parasitic loss-generating components (diesel engines and transmissions) from the power transmission system. By eliminating these intermediate components, the system achieves direct power transmission from the electric motor to the hydraulic pump, preventing parasitic losses and maximizing the available horsepower at the pump.
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 operational costs, minimizes noise, enhances efficiency by eliminating parasitic losses, and allows for continuous duty cycles, thereby reducing the duration and expense of fracking operations.
Implementation Method 1
a first Variable Frequency Drive (VFD) configured to convert electrical power from a first voltage level to electrical power at a second voltage level to drive a single shaft electric motor
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 pump configuration includes a single VFD configuration, the single shaft electric motor, and the single shaft hydraulic pump mounted on the single pump trailer. The single VFD configuration converts the electric power at the power generation voltage level distributed from the power distribution trailer to a VFD voltage level and drives the single shaft electric motor to control the operation of the single shaft electric motor and the single hydraulic pump. The VFD voltage level is a voltage level that is required to drive the single shaft electric motor. The VFD configuration also controls operation of the auxiliary systems based on the electric power at the auxiliary voltage level.