Variable frequency drive configuration for electric driven hydraulic fracking system

Patent metadata

Field	Value
Publication number	US-11939828-B2
Application number	US-202318370245-A
Country	US
Kind code	B2
Filing date	Sep 19, 2023
Priority date	Feb 14, 2019
Publication date	Mar 26, 2024
Grant date	Mar 26, 2024

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.

First claim

What is claimed is:

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 Variable Frequency Drive (VFD) configuration includes a plurality of VFD cells with each VFD cell isolated from each other VFD cell that is configured to:
segment an AC voltage signal that is associated with electric power generated at a power generation voltage level by a power generation system into a plurality of partitions to convert the AC voltage signal associated with the electric power at the power generation voltage level to a VFD voltage signal at a VFD voltage level based on the isolation of each VFD cell, wherein the VFD voltage level is a voltage level of that is required to drive an electric motor to control a hydraulic pump, and
reconnect each partition into a configuration that generates the VFD voltage signal at the VFD voltage level based on the isolation of each VFD cell to drive the electric motor to control an operation of the electric motor and the hydraulic pump with a decrease in a level of harmonics included in a VFD current waveform of the VFD voltage signal at the VFD voltage level.

2. The electric driven hydraulic fracking system of claim 1 , wherein the VFD configuration is further configured to:
mitigate the level of harmonics in the VFD current waveform included in the VFD voltage signal at the VFD voltage level, wherein the VFD voltage signal is associated with that is converted from the AC voltage signal that is associated with electric power generated by the power generation system; 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 1 , wherein the VFD configuration further comprises: a VFD transformer that is configured to:
apply a phase shift to a plurality of phase changing sinusoidal signals included in the AC voltage signal associated with the electric power at the power generation voltage level that is generated by the power generation system and received by the VFD configuration, and
convert the AC voltage signal associated with the electric power at the power generation voltage level to the VFD voltage signal at the VFD voltage level based on the phase shift of each of the sinusoidal signals included in the AC voltage signal associated with the electric power at the power generation voltage level to mitigate the level of harmonics in the VFD current waveform included in the VFD voltage signal at the VFD voltage level, wherein the isolation of each VFD cell from each other VFD cell enables the VFD transformer to provide the phase shift to the phase changing sinusoidal signals included in the AC voltage signal associated with the electric power at the power generation voltage level.

4. The electric driven hydraulic fracking system of claim 2 , wherein each VFD cell is further configured to:
convert a first phase of the AC voltage signal, a second phase of the AC voltage signal, and a third phase of the AC voltage signal to 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 decrease in harmonics included in the VFD current waveform of the VFD voltage signal at the VFD voltage level.

5. The electric driven hydraulic fracking system of claim 3 , wherein each VFD cell further comprises:
a plurality of windings with each plurality of windings isolated from each other plurality of windings that is configured to:
receive the AC voltage signal as the input power to the corresponding VFD cell as the first phase of the AC voltage signal, the second phase of the AC voltage signal, and the third phase of the AC voltage signal; and
segment the AC voltage signal received as the input power to the corresponding VFD cell into the plurality of partitions to convert the AC voltage signal to electric power at a VFD cell voltage level for each corresponding VFD cell, wherein the isolation of the plurality of windings from each other plurality of windings enables each corresponding VFD cell to generate the electric power at the VFD cell voltage level after each corresponding plurality of windings segments the AC voltage signal.

6. The electric driven hydraulic fracking system of claim 4 , wherein VFD configuration is further configured to:
reconnect the plurality of partitions of the segmented AC voltage signal by the corresponding plurality of windings as converted into the electric power at the VFD cell voltage level and generated by each corresponding VFD cell into 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 VFD voltage signal at the VFD voltage level as reconnected due to the isolation of each VFD cell from each other VFD cell with the decrease in harmonics included in the VFD current waveform of the VFD voltage signal at the VFD voltage level.

7. The electric driven hydraulic fracking system of claim 5 , wherein the VFD transformer is further configured to:
apply a phase shift to each of the plurality of partitions of the segmented AC voltage signal by each corresponding plurality of windings as converted into the electric power at the VFD cell voltage level as the partitions are reconnected into the VFD voltage signal at the VFD voltage level with the decrease in harmonics included in the VFD waveform of the VFD voltage signal at the VFD voltage level due to the isolation of each VFD cell from each other VFD cell.

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: segmenting by a Variable Frequency Drive (VFD) configuration an AC voltage signal that is associated with electric power generated at a power generation level by a power generation system into a plurality of partitions to convert the AC voltage signal associated with the electric power generated at the power generation voltage level to a VFD voltage signal at a VFD voltage level based on an isolation of each VFD cell from a plurality of VFD cells included in the VFD configuration, wherein the VFD voltage level is a voltage level that is required to drive an electric motor to control a hydraulic pump; and
reconnect each partition into a configuration that generates the VFD voltage signal at the VFD voltage level based on the isolation of each VFD cell to drive the electric motor to control an operation of the electric motor and the hydraulic pump with a decrease in a level of harmonics included in a VFD waveform of the VFD voltage signal at the VFD voltage level.

9. The method of claim 8 , further comprising:
mitigating the level of harmonics in the VFD current waveform included in the VFD voltage signal at the VFD voltage level, wherein the VFD voltage signal is converted from an AC voltage signal associated with the electric power that is generated by the power generation system; 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 motor at the VFD voltage level.

10. The method of claim 9 , further comprising:
applying by a VFD transformer a phase shift to a plurality of phase changing sinusoidal signals included in the AC voltage signal associated with the electric power at the power generation vol

Assignees

• Halliburton Energy Services Inc

Inventors

• Fischer John
• Crosetto John J
• Kubricht David
• Cheatham Richard
• Pollack Jeffrey
• Lawman Chad
• Todd David
• Nolen Tyler

Classifications

• H02J13/34

  the equipment being switches, relays or circuit breakers · CPC title

• H02J2105/37

  exchanging power with electric vehicles [EV] or with hybrid electric vehicles [HEV] · CPC title

• H02J7/54

  Passive balancing, e.g. using resistors or parallel MOSFETs · CPC title

• E21B43/2607

  Surface equipment specially adapted for fracturing operations · CPC title

• E21B21/08 Primary

  Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure (valve arrangements therefor E21B21/10) · CPC title