Electric Ancillary Drives for Hydraulic Fracturing Equipment
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Solution Overview
Problem
Hydraulic fracturing systems face inefficiencies and reliability issues due to the use of hydraulic motors, which result in irregular control systems, multiple pump installations for varying fluid rates, and potential hazards from hydraulic fluid, including contamination and noise pollution.
Innovation Solution
The implementation of electric motors with variable-frequency drives (VFDs) to power ancillary units in hydraulic fracturing systems, replacing hydraulic motors and fluid systems, allowing for precise speed control and reducing the need for multiple pump installations and hydraulic fluid handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hydraulic motors are used to power ancillary units, then mechanical power can be transmitted to various components, but the control system becomes irregular and unreliable due to charge pressure fluctuations
Solution Approach 1:
The patent replaces the hydraulic motor system with an electric motor system. Instead of using hydraulic motors that are susceptible to charge pressure fluctuations and require complex proportional valve control systems, the invention uses electric motors with electronic variable frequency drives. This substitution eliminates the irregular hydraulic control system while maintaining the ability to power ancillary units, thereby improving control reliability without sacrificing power transmission capability.
2Speed
If hydraulic motors are used to power chemical pumps, then pumps can operate at varying speeds, but multiple pumps of different sizes must be installed to achieve accurate control at different fluid rates
Solution Approach 1:
The patent implements a universal electric motor system that can power any ancillary unit including chemical pumps, augers, and mixers. Instead of installing multiple specialized hydraulic motors of different sizes for different fluid rates, the invention uses a single type of electric motor that can operate across a wide speed range through electronic control. This multi-functional approach allows one motor design to replace multiple specialized motors, reducing device complexity while maintaining speed variability capability.
Solution Approach 2:
The patent employs variable frequency drives (VFDs) to dynamically control the speed of electric motors in real-time. Instead of relying on fixed-speed motors or complex mechanical speed control mechanisms, the system uses electronic dynamic control to adjust motor speeds precisely. This dynamic control capability allows a single motor to perform the work of multiple fixed-speed motors, reducing the number of installations needed while maintaining the ability to operate at varying speeds for different fluid rates.
3Power
If hydraulic fluid systems are used, then power can be transmitted to ancillary equipment, but the system adds weight, requires dedicated radiators, and creates environmental contamination risks
Solution Approach 1:
The patent replaces the entire hydraulic fluid system with an electric power system. Instead of using hydraulic fluid under pressure to transmit power to ancillary equipment, the invention uses electrical power transmitted through wires to electric motors. This substitution eliminates the harmful aspects of hydraulic systems including environmental contamination risks from fluid leaks, the weight of hydraulic fluid and reservoirs, and the need for dedicated radiators. The electric system maintains power transmission capability while removing the harmful factors associated with hydraulic fluid.
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 steady operation of ancillary units at any speed, reduces maintenance time and costs, minimizes environmental impact, and decreases noise and weight, while eliminating the need for hydraulic fluid and associated equipment, leading to increased efficiency and reliability.
Implementation Method 1
The implementation of electric motors with variable-frequency drives (VFDs) to power ancillary units in hydraulic fracturing systems
Implementation Method 2
The implementation of electric motors with variable-frequency drives (VFDs) to power ancillary units in hydraulic fracturing systems
Data Source
AI summary
The present disclosure is directed to a hydraulic fracturing system for fracturing a subterranean formation. In an embodiment, the system can include an electric pump fluidly connected to a well associated with the formation, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the formation and fractures the formation. The system can further include one or more ancillary units associated with the fluid pumped into the wellbore. The system can further include a first motor electrically coupled to the electric pump to operate the electric pump, and one or more second motors, each of the second motors electrically coupled to each of the ancillary units to operate the one or more ancillary units.