Electric Multi-Plunger Fracturing Pump Layout for Variable Loads
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Solution Overview
Problem
Existing hydraulic fracturing systems rely heavily on diesel engines, which are expensive, environmentally unfriendly, and pose safety risks, while turbine systems are inefficient at fluctuating loads and require large footprints, making them undesirable for fracturing operations.
Innovation Solution
A modular system utilizing an electric-powered multi-plunger pump, such as a septuplex pump, with a variable frequency drive and transformer in a compact trailer configuration, allowing for efficient power distribution and reduced space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If diesel engines are used to power fracturing operations, then sufficient power is available, but the system becomes more expensive, environmentally harmful, and less safe
Solution Approach 1:
The patent replaces diesel mechanical engines with electric motors powered by natural gas turbines or renewable energy sources. This substitution eliminates diesel combustion, removing harmful emissions and safety risks associated with fuel storage and handling, while maintaining the required power output for fracturing operations
Solution Approach 2:
The invention changes the energy source parameter from diesel fuel to natural gas or renewable electricity. This parameter change transforms the system from a combustion-based mechanical power source to an electric power source, achieving both sufficient power and reduced environmental impact
2Object-affected harmful factors
If turbine systems are used to power fracturing operations, then environmental friendliness improves, but the footprint becomes larger and efficiency drops at fluctuating loads
Solution Approach 1:
The patent segments the power generation system into modular electric motor units that can be independently configured. This allows the system to be scaled to exact power requirements without the excessive footprint of traditional turbine systems, while maintaining environmental benefits through electric operation
Solution Approach 2:
The invention implements variable frequency drives and electronic control systems that allow electric motors to efficiently adapt to fluctuating load conditions. This dynamic control capability maintains efficiency across varying operational demands without requiring oversized equipment, reducing the overall system footprint
3Productivity
If traditional diesel systems are used, then pumping capacity is sufficient, but the equipment requires heavy transportation and constant refueling
Solution Approach 1:
The patent replaces diesel-powered pumping systems with electrically-powered systems. This substitution eliminates the need for diesel fuel storage tanks, refueling operations, and associated heavy-duty transportation infrastructure, while maintaining sufficient pumping capacity through properly sized electric motors
Solution Approach 2:
The invention creates a versatile power system that can operate from multiple energy sources including natural gas turbines, grid electricity, or renewable energy systems. This multi-functionality provides sufficient pumping capacity while eliminating the logistical complexity of diesel fuel supply chains
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
The system provides increased pumping capacity with a smaller footprint, improved safety, and reduced environmental impact by eliminating diesel reliance, while maintaining efficient operation at varying loads.
Implementation Method 1
powered by at least one electric motor
Implementation Method 2
a variable frequency drive and transformer in a compact trailer configuration, allowing for efficient power distribution
Implementation Method 3
a variable frequency drive and transformer in a compact trailer configuration, allowing for efficient power distribution
Data Source
AI summary
A hydraulic fracturing system includes a support structure having a first area at a first height and a second area at a second height, the first and second areas adjacent one another. The system also includes an electric powered, multi-plunger pump with an odd number of plungers, arranged in the first area, the electric powered pump coupled to a well, via outlet piping, and powered by at least one electric motor, also arranged in the first area. The system further includes a variable frequency drive (VFD), arranged in the second area, connected to the at least one electric motor, the VFD configured to control at least a speed of the at least one electric motor. The system also includes a transformer, arranged in the second area, the transformer positioned within an enclosure with the VFD, the transformer distributing power to the electric pump.