Single-Trailer VFD Fracking Pump Layout to Cut Parasitic Losses
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Solution Overview
Problem
Conventional hydraulic fracking systems rely on diesel engines, leading to increased costs, noise pollution, and operational inefficiencies due to the need for multiple engines, transmissions, and trailers, which also result in parasitic losses and higher manpower requirements.
Innovation Solution
Implementing an electric-driven hydraulic fracking system utilizing a single Variable Frequency Drive (VFD), a single shaft electric motor, and a single hydraulic pump on a single trailer, powered by a consolidated electric power generation system, reducing the number of power sources and trailers needed, and minimizing parasitic losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple diesel engines and transmissions are used to drive multiple hydraulic pumps, then the required horsepower is achieved, but the device complexity and quantity of components increase
Solution Approach 1:
The patent consolidates multiple diesel engines, transmissions, and hydraulic pumps into a single integrated electric motor and hydraulic pump system. The electric motor directly couples to the hydraulic pump, eliminating the need for separate engines and transmissions for each pump, thereby reducing component quantity while maintaining required horsepower.
Solution Approach 2:
The single electric motor serves as a universal power source that can drive multiple hydraulic pumps through direct coupling or belt drives. This multi-functional approach replaces multiple specialized diesel engines, each dedicated to a specific pump, with one versatile electric motor that can power the entire fracking system.
2Quantity of substance
If the power rating of hydraulic pumps is increased to reduce quantity, then fewer pumps are needed, but the power rating of diesel engines and transmissions must also increase
Solution Approach 1:
The patent replaces the mechanical diesel engine-transmission system with an electric motor system. This substitution allows for higher power ratings in a more compact and efficient package, enabling the use of fewer hydraulic pumps while avoiding the proportional increase in diesel engine power ratings that would be required.
3Ease of manufacture
If multiple trailers are used to transport and position configurations, then all components can be transported, but transportation cost and operational complexity increase
Solution Approach 1:
The patent combines multiple previously separate components (electric motor, hydraulic pump, control systems) into a single integrated assembly that can be transported on one trailer. This consolidation reduces the number of trailers needed from multiple to just one, simplifying logistics and reducing transportation costs while maintaining full functionality.
4Productivity
If diesel engines are used to drive hydraulic pumps, then the pumps can operate, but parasitic losses occur that decrease available horsepower
Solution Approach 1:
The patent replaces the diesel engine with an electric motor that directly drives the hydraulic pump. This substitution eliminates parasitic losses associated with diesel engine operation (such as auxiliary system power requirements and mechanical inefficiencies), thereby increasing the available horsepower for productive work.
5Power
If multiple diesel engines are positioned at the fracking site, then sufficient power is available, but noise levels and air quality issues increase
Solution Approach 1:
The patent substitutes diesel engines with an electric motor system that draws power from an external electrical source. This replacement eliminates the noise and air quality problems associated with diesel combustion while maintaining sufficient power output for the hydraulic fracking operation.
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, reduces noise pollution, enhances efficiency by eliminating parasitic losses, and simplifies logistics, allowing for continuous duty cycles and increased productivity in hydraulic fracking operations.
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.