Auxiliary Power Networks for Direct-Drive Turbine Fracturing Units
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Solution Overview
Problem
Hydraulic fracturing operations face inefficiencies and high capital costs due to the complexity and power requirements of diesel engine and electric fracturing systems, particularly in managing auxiliary equipment power needs, which are not adequately addressed by existing technologies.
Innovation Solution
The development of a direct drive turbine (DDT) hydraulic fracturing unit utilizing a dual fuel, dual shaft gas turbine engine with onboard auxiliary equipment driven by electric or hydraulic motors, and a power arrangement that includes engine-generator sets and hydraulic power networks to efficiently power auxiliary equipment, allowing for flexible power sources and redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If diesel engines are used to power hydraulic fracturing units, then sufficient power output (2000-3000 HHP) can be achieved, but device complexity and capital costs increase due to the need for multiple units and auxiliary equipment
Solution Approach 1:
The gas turbine engine serves multiple functions: it powers the main fracturing pump through the drivetrain while simultaneously driving generator sets through power take-off shafts to supply electrical power for auxiliary equipment. This multi-functionality eliminates the need for separate diesel engines and reduces overall system complexity.
Solution Approach 2:
The patent combines the power transmission system and electrical power generation system into a single integrated gas turbine platform. The power take-off shafts serve dual purposes of mechanical power transmission and electrical generation, merging previously separate systems into one cohesive unit.
2Power
If multiple diesel engine units are deployed to meet flow and pressure demands, then sufficient fracturing power can be achieved, but on-location congestion increases
Solution Approach 1:
A single gas turbine unit replaces multiple diesel engine units by simultaneously providing mechanical power for fracturing pumps and electrical power for auxiliary equipment through integrated generator sets, reducing the number of units required on location.
3Power
If conventional power arrangements are used for auxiliary equipment, then adequate power can be supplied, but operational costs increase due to inefficiency
Solution Approach 1:
The gas turbine engine serves itself by generating its own electrical power through integrated generator sets driven by its own power take-off shafts. This self-generated power supplies auxiliary equipment efficiently, eliminating the need for external power sources and reducing operational costs.
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 enables efficient operation of hydraulic fracturing units with higher horsepower output than conventional diesel or electric systems, reduced congestion, and lower operational costs by leveraging dual fuel gas turbines and integrated power networks to support auxiliary equipment, enhancing overall fracturing efficiency and reducing capital expenditures.
Implementation Method 1
a dual fuel, dual shaft gas turbine engine
Implementation Method 2
engine-generator sets
Implementation Method 3
hydraulic power networks
Data Source
AI summary
Embodiments of systems and methods disclosed provide a hydraulic fracturing unit that includes a reciprocating plunger pump configured to pump a fracturing fluid and a powertrain configured to power the reciprocating plunger pump. The powertrain includes a prime mover and a drivetrain, the prime mover including a gas turbine engine. The hydraulic fracturing unit also includes auxiliary equipment configured to support operation of the hydraulic fracturing unit including the reciprocating plunger pump and the powertrain. A power system is configured to power the auxiliary equipment. The power system includes a power source and a power network. The power source is configured to generate power for the auxiliary equipment. The power network is coupled to the power source and the auxiliary equipment, and configured to deliver the power generated by the power source to the auxiliary equipment. Associated systems including a plurality of hydraulic fracturing units are also provided.