Single-VFD Fracking Pump Configuration for Lower Parasitic Loss
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Solution Overview
Problem
Conventional hydraulic fracking systems rely on diesel engines, which require multiple engines and transmissions, leading to increased costs, parasitic losses, noise, and operational inefficiencies, and are difficult to operate in remote locations.
Innovation Solution
Implementing a single shaft electric motor and hydraulic pump configuration powered by a centralized electric power generation system, utilizing a single Variable Frequency Drive (VFD) to consolidate power distribution and reduce the number of diesel engines and transmissions, enabling continuous operation with reduced parasitic losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple diesel engines and transmissions are used to drive hydraulic pumps, then the required horsepower can be achieved, but the system complexity and operational costs increase significantly
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. This merging approach maintains the required total horsepower while significantly reducing system complexity by eliminating redundant engine and transmission components.
Solution Approach 2:
The single electric motor serves multiple functions by driving several hydraulic pumps simultaneously, replacing the need for individual diesel engines for each pump. This multi-functionality approach achieves the same power distribution with fewer components, reducing both complexity and maintenance requirements.
2Power
If multiple diesel engines are positioned at the fracking site, then the required power capacity is achieved, but the number of trailers and transportation requirements increase
Solution Approach 1:
The patent combines the function of multiple diesel engines into a single electric motor system, which can be transported on fewer or even a single trailer. This consolidation maintains the total power capacity needed while significantly reducing the quantity of transportation units required to deploy the system at the fracking site.
3Productivity
If diesel engines are used to drive hydraulic pumps, then the pumps can operate, but parasitic losses decrease the available horsepower
Solution Approach 1:
The patent replaces the mechanical diesel engine system with an electric motor system. This substitution eliminates the parasitic losses associated with diesel engine operation, such as friction, heat generation, and inefficiencies in the diesel combustion process, thereby increasing the effective horsepower available to drive the hydraulic pumps.
4Productivity
If multiple diesel engines and auxiliary systems are used, then the hydraulic pumps can be driven, but the noise levels and environmental impact increase
Solution Approach 1:
The patent substitutes diesel engines with electric motors to drive hydraulic pumps. This replacement significantly reduces noise levels and harmful emissions because electric motors operate much quieter and produce no direct exhaust emissions, thereby maintaining productivity while reducing environmental impact and noise pollution at the fracking site.
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 configuration reduces operational costs, increases efficiency, and allows for seamless integration with electric utility grids, minimizing environmental impact and enhancing productivity by maintaining continuous hydraulic pumping.
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
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.