Turbine Fracturing Pump Fleet Control Without a Spare Unit
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Solution Overview
Problem
Traditional diesel fracturing pumping fleets require a large footprint and additional auxiliary equipment, posing safety hazards and inefficiencies due to the need for a spare unit and excessive fuel consumption.
Innovation Solution
A system utilizing a fleet of directly driven turbine pump units, controlled by a controller, operates pump units at varying output powers to maintain hydraulic horsepower demand, eliminating the need for a spare unit and optimizing power usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a traditional diesel powered pumping fleet is used to achieve maximum rated horsepower, then the required power output is met, but the equipment footprint and auxiliary equipment requirements increase significantly
Solution Approach 1:
The patent merges the power transmission function by directly coupling the turbine engine to the pump via a driveshaft, eliminating the need for separate diesel engines, gearboxes, and auxiliary equipment. This direct drive configuration consolidates multiple components into a single integrated unit, reducing the overall equipment footprint while maintaining the required horsepower output.
2Reliability
If a spare pump unit is maintained on standby, then reliability is improved, but fuel consumption and equipment requirements increase
Solution Approach 1:
The patent implements dynamic operation where pump units can be quickly brought online or taken offline based on real-time hydraulic fracturing demands. The system operates with a flexible number of active pump units (N-1 configuration) rather than maintaining a fixed spare unit, allowing dynamic adjustment of fuel consumption and equipment usage while maintaining reliability through rapid unit replacement capability.
3Power
If multiple diesel engines are used to drive the pumps, then the required power is achieved, but safety hazards from auxiliary equipment increase
Solution Approach 1:
The patent extracts and eliminates the auxiliary equipment components (separate gearboxes, multiple diesel engines, and associated mechanical linkages) by implementing a direct drive system. This removal of hazardous auxiliary equipment reduces safety risks to employees while maintaining the required power output through the streamlined turbine-engine-to-pump direct coupling.
4Productivity
If pump units operate at maximum continuous power continuously, then hydraulic horsepower demand is met, but equipment wear and intermittent power capacity are not optimized
Solution Approach 1:
The patent applies parameter changes by operating pump units at variable power levels (70-100% of maximum continuous power) based on actual hydraulic fracturing demands rather than continuously at maximum capacity. The system can shift between operating modes (all units at first output power or some units at second output power) to optimize both productivity and equipment lifespan according to real-time needs.
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
Reduces equipment footprint, minimizes safety hazards, and enhances operational efficiency by dynamically adjusting pump unit output to meet hydraulic fracturing demands.
Implementation Method 1
Each of the pump units may include a turbine engine
Implementation Method 2
turbine engine, a driveshaft, a gearbox connected to the turbine engine and driveshaft
Data Source
AI summary
A system and method for operating a fleet of pumps for a turbine driven fracturing pump system used in hydraulic fracturing is disclosed. A method of operating a fleet of pumps associated with a hydraulic fracturing system includes receiving a demand Hydraulic Horse Power (HHP) signal. The demand HHP signal may include the Horse Power (HP) required for the hydraulic fracturing system to operate and may include consideration for frictional and other losses. The method further includes operating all available pump units at a percentage of rating below Maximum Continuous Power (MCP) level, based on the demand HHP signal. Furthermore, the method may include receiving a signal for loss of power from one or more pump units. The method further includes operating one or more units at MCP level and operating one or more units at Maximum Intermittent Power (MIP) level to meet the demand HHP signal.