Electric driven hydraulic fracking system

Patent metadata

Field	Value
Publication number	US-12460524-B2
Application number	US-202418664000-A
Country	US
Kind code	B2
Filing date	May 14, 2024
Priority date	Feb 14, 2019
Publication date	Nov 4, 2025
Grant date	Nov 4, 2025

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. The single VFD converts the electric power of at least 13.8 kV to a VFD rated voltage level of at least 4160V and drives the single shaft electric motor at the VFD voltage level of up to 4160V to control the operation of the single shaft electric motor and the single hydraulic pump. The single shaft electric motor drives the single hydraulic pump with the rotation at the rated RPM level of at least 750 RPM. The single hydraulic pump continuously pumps the fracking media into the well at the HP level of at least 5000 HP. The single hydraulic pump operates on a continuous duty cycle to continuously pump the fracking media at the HP level of at least 5000 HP.

First claim

What is claimed is:

1 . A hydraulic fracking system, comprising:
switchgears each configured to receive electric power at a first voltage level from a power generation system, and output electric power at the first voltage level; a transformer configured to receive electric power at the first voltage level from the power generation system, and output electric power at a second voltage level that is less than the first voltage level; and variable frequency drive (VFD) systems each configured to receive electric power at the first voltage level from one of the switchgears, receive electric power at the second voltage level from the transformer, use the received electric power at the second voltage level to receive a communication from a fracking control center, and use the received electric power at the first voltage level to respectively drive a motor mechanically coupled to a hydraulic pump based on the communication.

2 . The hydraulic fracking system of claim 1 , wherein each of the VFD systems is further configured to respectively drive the motor by converting the received electric power at the first voltage level to electric power at a third voltage level that is less than the first voltage level, and respectively providing the electric power at the third voltage level to the motor according to the communication.

3 . The hydraulic fracking system of claim 2 , wherein each of the VFD systems is further configured to convert the received electric power at the first voltage level to the electric power at the third voltage level by applying each phase changing sinusoidal signal of a plurality of phase changing sinusoidal signals at a phase shift relative to each other.

4 . The hydraulic fracking system of claim 2 , wherein the third voltage level is higher than the second voltage level.

5 . The hydraulic fracking system of claim 2 , wherein the first voltage level is in a range of 4160 V to 38 kV.

6 . The hydraulic fracking system of claim 2 , wherein the second voltage level is in a range of 24 to 480 V.

7 . The hydraulic fracking system of claim 2 , wherein the third voltage level is 4160 V or less.

8 . The hydraulic fracking system of claim 1 , wherein the fracking control center is configured to send the communication via a communication link between the fracking control center and the VFD systems.

9 . The hydraulic fracking system of claim 1 , wherein the communication comprises a wireless transmission for controlling the VFD systems.

10 . The hydraulic fracking system of claim 1 , wherein the communication comprises a wired transmission for controlling the VFD systems.

11 . The hydraulic fracking system of claim 1 , wherein the transformer is further configured to output electric power at the second voltage level to an auxiliary system.

12 . The hydraulic fracking system of claim 1 , wherein the transformer is further configured to output electric power at the second voltage level to the fracking control center.

13 . The hydraulic fracking system of claim 1 , wherein the switchgears and the transformer are disposed on a trailer.

14 . The hydraulic fracking system of claim 1 , wherein each of the VFD systems is respectively disposed on a trailer.

15 . The hydraulic fracking system of claim 14 , further comprising auxiliary systems and controllers configured to respectively control the auxiliary systems, wherein one of the auxiliary systems and one of the controllers are disposed on each trailer.

16 . The hydraulic fracking system of claim 15 , wherein each of the auxiliary systems is configured to receive electric power at the second voltage level from the transformer, and each of the controllers is configured to receive electric power at the second voltage level from the transformer.

17 . A method of hydraulic fracturing, comprising:
receiving, by switchgears, electric power at a first voltage level from a power generation system; outputting, by the switchgears, electric power at the first voltage level; receiving, by a transformer, electric power at the first voltage level from the power generation system; outputting, by the transformer, electric power at a second voltage level that is less than the first voltage level; receiving, by variable frequency drive (VFD) systems, electric power at the first voltage level from the switchgears; receiving, by the VFD systems, electric power at the second voltage level from the transformer; using, by the VFD systems, the received electric power at the second voltage level to receive a communication from a fracking control center; and using, by the VFD systems, the received electric power at the first voltage level to drive motors mechanically coupled to hydraulic pumps based on the communication, wherein the driving of the motors causes the hydraulic pumps to create hydraulic pressure; and fracturing a subsurface formation using the hydraulic pressure.

18 . The method of claim 17 , wherein
the using of the received electric power at the first voltage level to drive the motors comprises converting the received electric power at the first voltage level to electric power at a third voltage level that is less than the first voltage level, and providing the electric power at the third voltage level to the motors according to the communication, and the converting of the electric power at the first voltage level to the electric power at the third voltage level comprises applying each phase changing sinusoidal signal of a plurality of phase changing sinusoidal signals at a phase shift relative to each other.

19 . A hydraulic fracking system, comprising:
a motor; a hydraulic pump mechanically coupled to the motor; a power generation system configured to output electric power at a first voltage level; a switchgear configured to receive electric power at the first voltage level from the power generation system, and output electric power at the first voltage level; a transformer configured to receive electric power at the first voltage level from the power generation system, and output electric power at a second voltage level that is less than the first voltage level; a fracking control center configured to receive electric power at the second voltage level from the transformer, and use electric power at the second voltage level to send a communication; and a variable frequency drive (VFD) system configured to receive electric power at the first voltage level from the switchgear, receive electric power at the second voltage level from the transformer, use electric power at the second voltage level to receive a communication from the fracking control center, and use electric power at the first voltage level to drive the motor based on the communication.

20 . The hydraulic fracking system of claim 19 , wherein
the VFD system is further configured to drive the motor by converting electric power at the first voltage level to electric power at a third voltage level that is less than the first voltage level, and providing electric power at the third voltage level to the motor according to the communication, and the VFD system is further configured to convert electric power at the first voltage level to electric power at the third voltage level by applying each phase changing sinusoidal signal of a plurality of phase changing sinusoidal signals at a phase shift relative to each other.

Assignees

• Halliburton Energy Services Inc

Inventors

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

Classifications

• H02K7/18

  Structural association of electric generators with mechanical driving motors, e.g. with turbines · CPC title

• F04B17/06

  Mobile combinations · CPC title

• F04B17/03

  driven by electric motors · CPC title

• E21B43/2607 Primary

  Surface equipment specially adapted for fracturing operations · CPC title

• F04D13/06

  the pump being electrically driven · CPC title