IP Library Granted Patent US 11,125,034
Granted Patent B2
US 11,125,034 · App. 17/226,953 · Granted Sep 21, 2021

Variable frequency drive configuration for electric driven hydraulic fracking system

Inventors: John Fischer (Hempstead, TX); John J. Crosetto (Oak Forest, IL); David Kubricht (Cypress, TX); Richard Cheatham (Houston, TX); Jeffrey Pollack (Joliet, IL); Chad Lawman (Joliet, IL); David Todd (Houston, TX); Tyler Nolen (Houston, TX)
Assignee: National Service Alliance—Houston LLC
E21B21/08E21B4/04E21B7/022E21B43/2605E21B43/2607F04B17/03F04B17/06F04D13/0686H02B1/52H02B5/00H02J13/00036H02K7/18H02P27/04E21B4/02F05B2220/706F05B2240/941
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Quick Facts
Patent No.
US 11,125,034
App. No.
17/226,953
Granted
Sep 21, 2021
Kind
B2
Abstract

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.

Claims (53)

1. An electric driven hydraulic fracking system that pumps a fracking media into a fracking well to execute a fracking operation to extract a fluid from the fracking well, comprising:

a VFD configuration that is configured to:

receive electric power generated by a power generation system at a power generation voltage level and distributed from a power distribution trailer to the VFD configuration,

convert the electric power at the power generation voltage level to a VFD voltage level and drive an electric motor to control the operation of the electric motor and a hydraulic pump, wherein the VFD voltage level is a voltage level that is required to drive the electric motor to drive the hydraulic pump, and

control operation of a plurality of auxiliary systems based on electric power at an auxiliary voltage level distributed from the power distribution trailer, wherein the electric power at the auxiliary voltage level enables the plurality of auxiliary systems to operate.

2. The electric driven hydraulic fracking system of claim 1 , wherein the VFD configuration is further configured to:

apply a plurality of phase changing sinusoidal signals to a conversion of an AC voltage signal associated with the electric power at the power generation voltage level to a VFD voltage signal at the VFD voltage level to mitigate a level of harmonics in a VFD current waveform included in the VFD voltage signal at the VFD voltage level; and

drive the electric motor to control the operation of the electric motor and the hydraulic pump with the mitigated level of harmonics included in the VFD current waveform of the electric power at the VFD voltage level.

3. The electric driven hydraulic fracking system of claim 2 , wherein the VFD configuration is further configured to apply each phase changing sinusoidal signal at a phase shift relative to each other phase changing sinusoidal signal in transitioning the AC voltage signal to the VFD voltage signal to reduce the level of harmonics in the VFD current waveform included in the VFD voltage signal that propagate back to the power generation system to below a level of total harmonic distortion that satisfies IEEE-519.

4. The electric driven hydraulic fracking system of claim 3 , wherein the VFD configuration is further configured to reduce the level of harmonics introduced at a common point of coupling between the VFD configuration and the power generation system to enable the power generation system to provide the electric power at the power generation level and to prevent a disruption to the power generation system.

5. The electric driven hydraulic fracking system of claim 2 , wherein the VFD configuration comprises:

a VFD transformer that is configured to:

apply a phase shift to the plurality of phase changing sinusoidal signals included in the AC sinusoidal signal of the electric power at the power generation voltage level that is provided by the power distribution trailer to the VFD configuration, and

convert the electric power at the power generation voltage level to the electric power at the VFD voltage level based on the phase shift of each of the sinusoidal signals included in the AC voltage signal of the electric power at the power generation voltage level to mitigate the level of harmonics in a VFD current waveform included in the VFD voltage signal at the VFD voltage level.

6. The electric driven hydraulic fracking system of claim 5 , wherein the VFD transformer is further configured to:

receive the electric power at the power generation voltage level and the electric power at the auxiliary voltage level as distributed by the power distribution trailer; and

pre-charge a plurality of capacitors associated with the VFD configuration to a voltage threshold with the electric power at the auxiliary voltage level to prevent an in-rush current that propagates to the power generation system after the VFD transformer provides the electric power at the power generation voltage level to the VFD configuration before the capacitors are pre-charged to a voltage threshold, wherein the voltage threshold is a percentage of the power generation voltage level that the capacitors are to be pre-charged to prevent the in-rush current after the VFD transformer provides the electric power at the power generation voltage level.

7. The electric driven hydraulic fracking system of claim 1 , wherein the power generation system comprises an electric utility power plant that is configured to:

generate the electric power at a power generation level of 24MW and a power generation voltage level of 12.47 kV, wherein the electric utility power plant is a power plant that independently generates electric power for an electric utility grid.

8. A method for an electric driven hydraulic fracking system that pumps a fracking media into a fracking well to execute a fracking operation to extract a fluid from the fracking well, comprising:

receiving by a VFD configuration electric power generated by a power generation system at a power generation voltage level and distributed from a power distribution trailer to the VFD configuration;

converting by the VFD configuration the electric power at the power generation voltage level to a VFD voltage level and drive an electric motor to control the operation of the electric motor and a hydraulic pump, wherein the VFD voltage level is a voltage level that is required to drive the electric motor to drive the hydraulic pump; and

controlling operation of a plurality of auxiliary systems based on electric power at an auxiliary voltage level distributed from the power distribution trailer, wherein the electric power at the auxiliary voltage level enables the plurality of auxiliary systems to operate.

9. The method of claim 8 , wherein the converting comprises:

applying a plurality of phase changing sinusoidal signals to a conversion of an AC voltage signal associated with the electric power at the power generation voltage level to a VFD voltage signal associated with the electric power at the power generation voltage level to a VFD voltage signal at the VFD voltage level to mitigate a level of harmonics in a VFD current waveform included in the VFD voltage signal at the VFD voltage level; and

driving the electric motor to control the operation of the electric motor and the hydraulic pump with the mitigated level of harmonics included in the VFD current waveform of the electric power at the VFD voltage level.

10. The method of claim 9 , wherein the converting further comprises:

applying each phase changing sinusoidal signal at a phase shift relative to each other phase changing sinusoidal signal in transitioning the AC voltage signal to the VFD voltage signal to reduce the level of harmonics in the VFD current waveform included in the VFD voltage signal that propagates back to the power generation system to below a level of total harmonic distortion that satisfies IEEE-519.

11. The method of 10 , wherein the converting further comprises:

reducing the level of harmonics introduced at a common point of coupling between the VFD and the power generation system to enable the power generation system to provide the electric power at the power generation voltage level to prevent a disruption to the power generation system.

12. The method of claim 9 , wherein the converting further comprises:

applying by a VFD transformer a phase shift to the plurality of phase changing sinusoidal signals included in the AC sinusoidal signal of the electric power at the power generation voltage level that is provided by the power distribution trailer to the VFD configuration; and

converting the electric power at the power generation voltage level to the electric power at the VFD voltage level based on the phase shift of each of the sinusoidal signals included in the AC voltage signal of the electric power at the power generation voltage level to mitigate the level of harmonics in a VFD current waveform included in the VFD voltage signal at the VFD voltage level.

13. The method of claim 12 , further comprising:

receiving the electric power by the VFD transformer at the power generation voltage level and the electric power at the auxiliary voltage level as distributed by the power distribution trailer; and

pre-charging a plurality of capacitors associated with the VFD configuration to a voltage threshold with the electric power at the auxiliary voltage level to prevent an in-rush current that propagates to the power generation system after the VFD transformer provides the electric power at the power generation voltage level to the VFD configuration before the capacitors are pre-charged to a voltage threshold, wherein the voltage threshold is a percentage of the power generation voltage level that the capacitors are to be pre-charged to prevent the in-rush current after the VFD transformer provides the electric power at the power generation voltage level.

14. The method of claim 8 , wherein the generating of electric power comprises:

generating the electric power at a power generation voltage level of 24MW and a power generation voltage level of 12.47 kV, wherein the electric utility power plant is a power plant that independently generates electric power for an electric utility grid.

15. An electric driven hydraulic fracking system that pumps a fracking media into a fracking well to execute a fracking operation to extract a fluid from the fracking well, comprises:

a plurality of VFD configurations with each VFD configuration configured to:

receive electric power generated by a power generation system at a power generation voltage level and distributed from a power distribution trailer to the plurality of VFD configurations,

convert the electric power at the power generation voltage level to a VFD voltage level and drive a corresponding electric motor from a plurality of electric motors to control the operation of each corresponding electric motor and a corresponding hydraulic pump from a plurality of hydraulic pumps, wherein the VFD voltage level is a voltage level that is required to drive the corresponding electric motor to drive the hydraulic pump, and

control operation of a plurality of auxiliary systems based on electric power at the at an auxiliary voltage level distributed from the power distribution trailer, wherein the electric power at the auxiliary voltage level enables the plurality of auxiliary systems to operate.

16. The electric driven hydraulic fracking system of claim 15 , wherein each VFD configuration is further configured to:

apply a plurality of phase changing sinusoidal signals to a conversion of a corresponding AC voltage signal associated with the electric power at the power generation voltage level to a corresponding VFD voltage signal at the VFD voltage level to mitigate a level of harmonics in a VFD current waveform included in each corresponding VFD voltage signal at the VFD voltage level; and

drive each corresponding electric motor to control the operation of each corresponding electric motor and each corresponding hydraulic pump with the mitigated level of harmonics included in the VFD current waveform of the electric power at the VFD voltage level.

17. The electric driven hydraulic fracking system of claim 16 , wherein each VFD configuration is further configured to apply each phase changing sinusoidal signal at a phase shift relative to each other phase changing sinusoidal signal in transitioning each corresponding AC voltage signal to each corresponding VFD voltage signal to reduce the level of harmonics in the VFD current waveform included in each corresponding VFD voltage signal that propagates back to the power generation system to below a level of total harmonic distortion that satisfies IEEE-519.

18. The electric driven hydraulic fracking system of claim 17 , wherein each VFD configuration is further configured to reduce the level of harmonics introduced at a common point of coupling between each VFD configuration and the power generation system to enable the power generation system to provide the electric power at the power generation voltage level to prevent disruption of the power generation system.

19. The electric driven hydraulic fracking system of claim 16 , wherein each VFD configuration comprises:

a VFD transformer that is configured to:

apply a phase shift to the plurality of phase changing sinusoidal signals included in each corresponding AC sinusoidal signal of the electric power at the power generation voltage level that is provided by the power distribution trailer to each corresponding VFD configuration, and

convert the electric power at the power generation voltage level to the electric power at the VFD voltage level based on the phase shift of each of the sinusoidal signals included in each corresponding AC voltage signal of the electric power at the power generation voltage level to mitigate the level of harmonics in the VFD current waveform included in each corresponding VFD voltage signal at the VFD voltage level.

20. The electric driven hydraulic fracking system of claim 16 , wherein the power generation system comprises an electric utility power plant that is configured to: generate the electric power at a power generation level of 24MW and a power generation voltage level of 12.47 kV, wherein the electric utility power plant is a power plant that independently generates electric power for an electric utility grid.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 26, 2023
From: NATIONAL SERVICE ALLIANCE HOUSTON, LLC
To: HALLIBURTON ENERGY SERVICES, INC.
Reel/Frame 065359/0658 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 9, 2021
From: FISCHER, JOHN; CROSETTO, JOHN J.; KUBRICHT, DAVID; CHEATHAM, RICHARD; POLLACK, JEFFREY; LAWMAN, CHAD; TODD, DAVID; NOLEN, TYLER
To: NATIONAL SERVICE ALLIANCE - HOUSTON LLC
Reel/Frame 055881/0799 →
Continuity (5)
Continuation 17134860 · Dec 28, 2020
Continuation 16943719 · Jul 30, 2020
Continuation 16790581 · Feb 13, 2020
Provisional Application 62805521 · Feb 14, 2019
Related Publication 20210222503A1 · Jul 22, 2021
Cited By (7)
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