Parameter monitoring and control for an electric driven hydraulic fracking system
An electric driven hydraulic fracking system is disclosed. A pump configuration includes the single VFD, the single shaft electric motor, and the single hydraulic pump mounted on the single pump trailer. A controller associated with the single VFD and is mounted on the single pump trailer. The controller monitors operation parameters associated with an operation of the electric driven hydraulic fracking system as each component of the electric driven hydraulic fracking system operates to determine whether the operation parameters deviate beyond a corresponding operation parameter threshold. Each of the operation parameters provides an indicator as to an operation status of a corresponding component of the electric driven hydraulic fracking system. The controller initiates corrected actions when each operation parameter deviates beyond the corresponding operation threshold. Initiating the corrected actions when each operation parameter deviates beyond the corresponding operation threshold maintains the operation of the electric driven hydraulic fracking system.
1. An electric driven hydraulic fracking system to pump a fracking media into a well to execute a fracking operation to extract a fluid from the well, comprising:
a VFD is configured to convert electric power at a power generation voltage level distributed from a power distribution trailer to a VFD voltage level and drive an electric motor that is associated with the VFD at the VFD voltage level to control the operation of the electric motor to drive a hydraulic pump associated with the VFD and the electric motor, wherein the VFD voltage level is a voltage level that is required to drive the electric motor, and
a controller associated with the VFD is configured to:
monitor a plurality of operation parameters associated with an operation of the electric driven hydraulic fracking system as each component of the electric driven hydraulic fracking system operates to determine whether at least one operation parameter deviates beyond at least one corresponding operation parameter threshold, wherein each of the operation parameters provides an indicator as to an operation status of a corresponding component of the electric driven hydraulic fracking system, and
initiate at least one corrected action when each operation parameter deviates beyond the at least one corresponding operation threshold, wherein initiating the at least one corrected action when each operation parameter deviates beyond the at least one corresponding operation threshold maintains the operation of the electric driven hydraulic fracking system.
2. The electric driven hydraulic fracking system of claim 1 , wherein the controller is further configured to:
monitor a VFD temperature parameter of the VFD to determine whether a VFD temperature associated with the VFD exceeds a VFD temperature threshold, wherein the VFD temperature threshold is indicative that the VFD temperature requires a corrective action of cooling the VFD when the VFD temperature exceeds the VFD temperature threshold; and
automatically activate a plurality of fans associated with the VFD to decrease the VFD temperature to below the VFD temperature threshold when the VFD temperature exceeds the temperature threshold; and
automatically deactivate the plurality of fans associated with the VFD when the VFD temperature decreases below the VFD temperature threshold.
3. The electric driven hydraulic fracking system of claim 1 , wherein the controller is further configured to:
monitor an electric motor temperature parameter of the electric motor to determine whether an electric motor temperature associated with the electric motor exceeds an electric motor temperature threshold, wherein the electric motor threshold is indicative that the electric motor temperature requires a corrective action of cooling the electric motor when the electric motor temperature exceeds the electric motor threshold;
automatically activate a plurality of fans associated with the electric motor to decrease the electric motor temperature to below the electric motor temperature threshold when the electric motor temperature exceeds the electric motor temperature threshold; and
automatically deactivate the plurality of fans associated with the electric motor when the electric motor temperature decreases below the electric motor temperature threshold.
4. The electric driven hydraulic fracking system of claim 3 , wherein the controller is further configured to:
determine whether each electric motor temperature parameter measured by each corresponding motor temperature sensor exceeds a shutdown electric motor temperature threshold, wherein the shutdown electric motor threshold is indicative that the electric motor temperature requires a corrective action of deactivating the electric motor when the electric motor temperature measured by each corresponding motor temperature sensor exceeds the shutdown electric motor threshold; and
automatically deactivate the electric motor when each electric motor temperature parameter measured by each corresponding motor temperature sensor exceeds the shutdown electric motor temperature threshold to prevent damage to the electric motor.
5. The electric driven hydraulic fracking system of claim 4 , further comprising:
a fracking control center that is configured to:
monitor a plurality of operation parameters associated with an operation of the electric driven hydraulic fracking system as each component of the electric driven hydraulic fracking system operates to determine whether at least one operation parameter deviates beyond the at least one corresponding operation parameter threshold, and
override the controller when the plurality of operation parameters indicate that the at least one corrected action initiated by the controller is not required to maintain the operation of the electric driven hydraulic fracking system.
6. The electric driven hydraulic fracking system of claim 5 , wherein the fracking control center is further configured to:
determine whether each electric motor temperature parameter measured by each corresponding motor temperature sensor that exceeds a shutdown electric motor temperature threshold is negatively operating when at least one electric motor temperature parameter measured by at least one corresponding motor temperature sensor is below the shutdown electric motor temperature threshold and at least one electric motor temperature parameter measured by at least one corresponding motor temperature sensor exceeds the shutdown electric motor temperature threshold; and
override the deactivation of the electric motor by the controller when the fracking control center determines that each motor temperature sensor that measures each corresponding motor temperature parameter that exceeds the shutdown electric motor temperature threshold is negatively operating, wherein shutdown of the electric motor is not required when each motor temperature sensor that measures each corresponding motor temperature parameter is negatively operating.
7. The electric driven hydraulic fracking system of claim 1 , wherein the controller is further configured to:
monitor a hydraulic pump temperature parameter of the hydraulic pump to determine whether a hydraulic pump temperature associated with the hydraulic pump exceeds a hydraulic pump threshold, wherein the hydraulic pump threshold is indicative that the hydraulic pump requires a corrective action of cooling the hydraulic pump when the hydraulic pump temperature exceeds the hydraulic pump threshold;
automatically activate a plurality of fans associated with the hydraulic pump to decrease the hydraulic pump threshold to below the hydraulic pump threshold when the hydraulic pump temperature exceeds the hydraulic pump threshold; and
automatically deactivate the plurality of fans associated with the hydraulic pump when the hydraulic pump temperature decreases below the hydraulic pump temperature threshold.
8. The electric driven hydraulic fracking system of claim 1 , wherein the controller is further configured to:
monitor a pressure parameter associated with a well head of the well as the fracking media is continuously injected into the well to determine whether a pressure associated with the well head of the well exceeds a pressure threshold, wherein the pressure threshold is indicative that the pressure associated with the well head requires a corrective action of decreasing an operation of the electric motor driving the hydraulic pump when the pressure associated with the well head exceeds the pressure threshold;
automatically decrease the operation of the electric motor to decrease the drive of the hydraulic pump to decrease the pressure associated with the well head to below the pressure threshold when the pressure associated with the well head exceeds the pressure threshold; and
automatically increase the operation of the electric motor to increase the drive of the hydraulic pump when the pressure associated with the well head decreases below the pressure threshold.
9. The electric driven hydraulic fracking system of claim 1 , wherein the controller is further configured to:
monitor a plurality of component temperature parameters to determine whether each component temperature parameter associated with corresponding components positioned inside of an enclosure positioned on a pump trailer to determine whether each component temperature parameter exceeds a corresponding component temperature threshold, wherein the enclosure houses components associated with the electric driven hydraulic fracking system and positioned on the pump trailer;
automatically deactivate at least one component housed in the enclosure when the corresponding component temperature parameter exceeds the corresponding component temperature threshold, wherein the corresponding temperature threshold is indicative that operation of the at least one component with the corresponding component temperature exceeding the corresponding component temperature threshold requires the corrective action of shutting down the at least one component; and
automatically activate each component housed in the enclosure when the corresponding component temperature parameter of each component is below the component temperature threshold.
10. The electric driven hydraulic fracking system of claim 9 , wherein the controller is further configured to:
monitor an enclosure temperature parameter of the enclosure positioned on the pump trailer to determine whether an enclosure temperature associated with the enclosure is below an enclosure temperature threshold, wherein the enclosure temperature threshold is indicative that the enclosure temperature requires a corrective action of heating the enclosure to activate the VFD when the enclosure temperature exceeds the enclosure temperature threshold;
automatically activate a plurality of auxiliary heaters positioned in the enclosure to increase the enclosure temperature to above the enclosure temperature threshold when the enclosure temperature is below the enclosure temperature threshold; and
automatically activate the VFD when the enclosure temperature is above the enclosure temperature threshold.
11. A method for an electric driven hydraulic fracking system to pump a fracking media into a well to execute a fracking operation to extract fluid from the well, comprising:
converting by a VFD electric power at a power generation voltage level distributed from a power distribution trailer to a VFD voltage level and drive an electric motor that is associated with the VFD at the VFD voltage level to control the operation of the electric motor to drive a hydraulic pump associated with the VFD and the electric motor, wherein the VFD voltage level is a voltage level that is required to drive the electric motor;
monitoring by a controller a plurality of operation parameters associated with an operation of the electric driven hydraulic fracking system as each component of the electric driven hydraulic fracking system operates to determine whether at least one operation parameter deviates beyond at least one corresponding operation parameter threshold, wherein each of the operation parameters provides an indicator as to an operation status of a corresponding component of the electric driven hydraulic fracking system; and
initiating at least one corrected action when each operation parameter deviates beyond the at least one corresponding operation threshold, wherein initiating the at least one corrected action when each operation parameter deviates beyond the at least one corresponding operation threshold maintains the operation of the electric driven hydraulic fracking system.
12. The method of claim 11 , further comprising:
monitoring a VFD temperature parameter of the VFD to determine whether a VFD temperature associated with the VFD exceeds a VFD temperature threshold, wherein the VFD temperature threshold is indicative that the VFD temperature requires a corrective action of cooling the VFD when the VFD temperature exceeds the VFD temperature threshold;
automatically activating a plurality of fans associated with the VFD to decrease the VFD temperature to below the VFD temperature threshold when the VFD temperature exceeds the temperature threshold; and
automatically deactivating the plurality of fans associated with the VFD when the VFD temperature decreases below the VFD temperature threshold.
13. The method of claim 11 , further comprising:
monitoring an electric motor temperature parameter of the electric motor to determine whether an electric motor temperature associated with the electric motor exceeds an electric motor temperature threshold, wherein the electric motor threshold is indicative that the electric motor requires a corrective action of cooling the electric motor when the electric motor temperature exceeds the electric motor threshold;
automatically activating a plurality of fans associated with the electric motor to decrease the electric motor temperature to below the electric motor temperature threshold when the electric motor temperature exceeds the electric motor temperature threshold; and
automatically deactivating the plurality of fans associated with the electric motor when the electric motor temperature decreases below the electric motor temperature threshold.
14. The method of claim 13 , further comprising:
determining whether each electric motor temperature parameter measured by each corresponding motor temperature sensor exceeds a shutdown electric motor temperature threshold, wherein the shutdown electric motor threshold is indicative that the electric motor temperature requires a corrective action of deactivating the electric motor when the electric motor temperature measured by each corresponding motor temperature sensor exceeds the shutdown electric motor threshold; and
automatically deactivating the electric motor when each electric motor temperature parameter measured by each corresponding motor temperature sensor exceeds the shutdown electric motor temperature threshold to prevent damage to the electric motor.
15. The method of claim 14 , further comprising:
monitoring by a fracking control center a plurality of operation parameters associated with an operation of the electric driven hydraulic fracking system as each component of the electric driven hydraulic fracking system operates to determine whether at least one operation parameter deviates beyond the at least one corresponding operation parameter threshold; and
overriding the controller when the plurality of operation parameters indicate that the at least one corrected action initiated by the controller is not required to maintain the operation of the electric driven hydraulic fracking system.
16. The method of claim 15 , further comprising:
determining whether each electric motor temperature parameter measured by each corresponding motor temperature sensor that exceeds a shutdown electric motor temperature threshold is negatively operating when at least one electric motor temperature parameter measured by at least one corresponding motor temperature sensor is below the shutdown electric motor temperature threshold and at least one electric motor temperature parameter measured by at least one corresponding motor temperature sensor exceeds the shutdown electric motor temperature threshold; and
overriding the deactivation of the electric motor by the controller when the fracking control center determines that each motor temperature sensor that measures each corresponding motor temperature parameter that exceeds the shutdown electric motor temperature threshold is negatively operating, wherein shutdown of the electric motor is not required when each motor temperature sensor that measures each corresponding motor temperature parameter is negatively operating.
17. The method of claim 11 , further comprising:
monitoring a hydraulic pump temperature parameter of the hydraulic pump to determine whether a hydraulic pump temperature associated with the hydraulic pump exceeds a hydraulic pump threshold, wherein the hydraulic pump threshold is indicative that the hydraulic pump requires a corrective action of cooling the hydraulic pump when the hydraulic pump temperature exceeds the hydraulic pump threshold;
automatically activating a plurality of fans associated with the hydraulic pump to decrease the hydraulic pump threshold to below the hydraulic pump threshold when the hydraulic pump temperature exceeds the hydraulic pump threshold; and
automatically deactivating the plurality of fans associated with the hydraulic pump when the hydraulic pump temperature decreases below the hydraulic pump temperature threshold.
18. The method of claim 11 , further comprising:
monitoring a pressure parameter associated with a well head of the well as the fracking media is continuously injected into the well to determine whether a pressure associated with the well head of the well exceeds a pressure threshold, wherein the pressure threshold is indicative that the pressure associated with the well head requires a corrective action of decreasing an operation of the electric motor driving the hydraulic pump when the pressure associated with the well head exceeds the pressure threshold;
automatically decreasing the operation of the electric motor to decrease the drive of the hydraulic pump to decrease the pressure associated with the well head to below the pressure threshold when the pressure associated with the well head exceeds the pressure threshold; and
automatically increasing the operation of the electric motor to increase the drive of the hydraulic pump when the pressure associated with the well head decreases below the pressure threshold.
19. The method of claim 18 , further comprising:
monitoring a plurality of component temperature parameters to determine whether each component temperature parameter associated with corresponding components positioned inside of an enclosure positioned on a pump trailer to determine whether each component temperature parameter exceeds a corresponding component temperature threshold, wherein the enclosure houses components associated with the electric driven hydraulic fracking system and positioned on the pump trailer;
automatically deactivating at least one component housed in the enclosure when the corresponding component temperature parameter exceeds the corresponding component temperature threshold, wherein the corresponding temperature threshold is indicative that operation of the at least one component with the corresponding component temperature exceeding the corresponding component temperature threshold requires the corrective action of shutting down the at least one component; and
automatically activating each component housed in the enclosure when the corresponding component temperature parameter of each component is below the component temperature threshold.
20. The method of claim 19 , further comprising:
monitoring an enclosure temperature parameter of the enclosure positioned on the pump trailer to determine whether an enclosure temperature associated with the enclosure is below an enclosure temperature threshold, wherein the enclosure temperature threshold is indicative that the enclosure temperature requires a corrective action of heating the enclosure to activate the VFD when the enclosure temperature exceeds the enclosure temperature threshold;
automatically activating a plurality of auxiliary heaters positioned in the enclosure to increase the enclosure temperature to above the enclosure temperature threshold when the enclosure temperature is below the enclosure temperature threshold; and
automatically activating the VFD when the enclosure temperature is above the enclosure temperature threshold.