Trailer-Mounted VFD Cabin for Dust-Resistant Electric Fracking
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Solution Overview
Problem
Conventional hydraulic fracking systems rely on diesel engines, leading to increased costs, inefficiencies, and noise due to the need for multiple diesel engines, transmissions, and hydraulic pumps, as well as parasitic losses that reduce the operational efficiency and extend the duration of fracking operations.
Innovation Solution
The implementation of an electrically-driven hydraulic fracking system using a variable frequency drive (VFD) cabin mounted on a mobile trailer, which includes a medium-voltage VFD and a ventilation system, directly coupled to the trailer chassis without suspension, to efficiently power hydraulic pumps with electric power generated by gas turbine engines, reducing the need for diesel engines and transmissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple diesel engines and transmissions are used to drive hydraulic pumps, then the required horsepower is achieved, but the operational cost and complexity increase significantly
Solution Approach 1:
The patent consolidates multiple diesel engines and transmissions into a single electric motor that drives all hydraulic pumps through a common electrical power source. This merging approach maintains the required total horsepower while significantly reducing the number of individual powertrain components at the fracking site.
Solution Approach 2:
The invention replaces the mechanical diesel engine-transmission system with an electrical motor-driven system. Instead of using multiple diesel engines mechanically connected to transmissions and hydraulic pumps, the system uses electric motors that can be centrally controlled and distributed, eliminating the need for multiple diesel powertrains.
2Power
If the number of hydraulic pumps is increased to achieve required horsepower, then the power requirement is met, but the number of diesel engines and transmissions must also increase
Solution Approach 1:
The electric motor system serves multiple functions simultaneously - it can drive multiple hydraulic pumps through a single power source, provide centralized control, and eliminate the need for individual diesel engines at each pump location. This multi-functionality reduces the overall quantity of equipment required.
3Adaptability or versatility
If more trailers are used to transport and position the increased assets, then the equipment can be deployed, but the operational cost and manpower requirements increase
Solution Approach 1:
The invention extracts the diesel engines and transmissions from the hydraulic pump assemblies, separating the power generation function (electric motor) from the hydraulic function. This allows the hydraulic pumps to be transported and positioned independently without requiring dedicated diesel powertrains at each location, reducing the number of trailers and deployment complexity.
4Productivity
If diesel engines are used to drive hydraulic pumps, then the pumps can operate, but parasitic losses occur that decrease the available horsepower and efficiency
Solution Approach 1:
The patent replaces the diesel engine mechanical drive system with an electric motor system that directly drives the hydraulic pumps. This substitution eliminates the parasitic losses associated with diesel engines, including those from auxiliary systems, transmissions, and mechanical coupling, thereby increasing the available horsepower and overall system efficiency.
5Productivity
If the duration of fracking operation is extended due to efficiency losses, then the operation can complete, but the operational cost increases significantly
Solution Approach 1:
The electric motor system enables continuous operation of hydraulic pumps without the efficiency losses and interruptions associated with diesel engines. The system maintains consistent power delivery and operational efficiency throughout the fracking process, reducing the total time required to complete the operation and associated 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 decreases operational costs, enhances efficiency by minimizing parasitic losses, and reduces noise levels, allowing for continuous duty cycles of hydraulic pumps, thereby increasing the efficiency and reducing the duration of fracking operations.
Implementation Method 1
the ventilation system is configured to generate an overpressure condition within the cabin to discourage the entry of dust and debris into the cabin
Implementation Method 2
one or more components of the medium-voltage VFD are coupled to the floor of the cabin via a vibration damping system
Data Source
AI summary
Certain embodiments of the present application relate to a variable frequency drive (VFD) cabin for a pump configuration including a mobile trailer on which the VFD cabin is to be mounted. The VFD cabin generally includes a medium-voltage VFD and a ventilation system. In certain embodiments, the ventilation system is configured to generate an overpressure condition within the cabin to discourage the entry of dust and debris into the cabin. In certain embodiments, one or more components of the medium-voltage VFD are coupled to the floor of the cabin via a vibration damping system. In certain embodiments, the VFD cabin may be directly coupled to a chassis of the mobile trailer without an intervening suspension being provided between the VFD cabin and the chassis.