Fracking Mobile Substation: Innovation & Sustainability Case Study
In July 2020, Electronic Power Design (EPD) delivered a groundbreaking mobile substation designed specifically for fracking operations.
This custom solution marks a significant shift in how energy is managed during fracking, replacing traditional power sources like generators and turbines with a more efficient and environmentally friendly configuration.
By integrating local utilities with modular medium voltage switchgear, EPD has created a first-of-its-kind mobile substation that is poised to revolutionize fracking and beyond.
This project showcases EPD’s commitment to innovation, customization, and sustainability, offering a glimpse into the future of electrical solutions for industrial applications.
Benefits of E-Fracking: A Game-Changer for the Industry
E-fracking offers multiple advantages over traditional methods, ranging from operational efficiency to environmental sustainability:
Operational Convenience
Unlike conventional fracking, which depends on generators and turbines, e-fracking leverages stable power from utilities. This eliminates ongoing logistics for fuel supply and reduces downtime.
Enhanced Mobility
The lightweight design of the power unit trailer reduces transportation challenges. It enables faster, easier movement over rugged terrains without requiring special highway permits.
Cost Effectiveness
With minimal maintenance requirements for transformers, switchgear, and VFD drives, e-fracking significantly lowers operational costs. While initial setup costs may vary based on location, the long-term savings make it a competitive alternative.
Environmental Responsibility
E-fracking eliminates greenhouse gas emissions, noise pollution, and soot, contributing to a safer, healthier working environment and aligning with corporate social responsibility goals.
Mobile Substation Design Features
The mobile substation delivered by EPD reflects a thoughtful integration of safety, functionality, and client-specific customization. Key features include:
Innovative Configuration
The substation comprises a trailer, a multiple winding step-down transformer, and modular medium voltage switchgear. This tailored configuration is designed to handle high-power loads efficiently while maintaining a compact footprint, a crucial aspect for fracking and other remote operations.
Safety and Efficiency
The trailer’s two-room design separates the transformer from the switchgear, ensuring safe operations by isolating live voltage. Additionally, the external control console allows operators to manage the substation remotely, enhancing operational convenience while minimizing risks associated with confined spaces.
Phase-Shifting Transformer Design
The transformer supplies three-phase power to each electronic pumping unit, ensuring evenly distributed loads. This phase-shifting capability reduces harmonic currents and voltage distortion, preventing disruptions to grid stability and improving operational efficiency.
Modular Medium Voltage Switchgear
The modular switchgear is designed to be highly reliable, with live voltage insulation to ensure safety and longevity. Its flexibility allows for quick maintenance and minimal downtime, ensuring uninterrupted power supply in demanding environments.
Challenges Overcome: Innovation Under Pressure
This project presented unique challenges, including an ambitious 16-week timeline and a completely novel design configuration.
Accelerated Timelines
To meet the tight schedule, EPD’s team expedited the design phase and secured customized components with reduced lead times through close collaboration with suppliers.
Pioneering Design
Creating a configuration never built before required engineering ingenuity. The team meticulously planned every detail, from wire routing to component placement, to ensure the unit met safety, functionality, and operational goals.
Dynamic Problem-Solving in Real-Time
EPD’s team faced unexpected hurdles during the project, such as sourcing components with traditionally long lead times. Through real-time problem-solving and proactive communication with suppliers, the team secured the necessary materials ahead of schedule. This agile approach ensured that the project stayed on track despite tight deadlines and logistical constraints.
Engineering Ingenuity and Team Collaboration
The groundbreaking configuration demanded exceptional collaboration among engineers, designers, and project managers. EPD’s multidisciplinary team worked closely to optimize safety, performance, and operational functionality. Leveraging advanced modeling tools and in-depth technical expertise, they delivered a first-of-its- kind mobile substation that exceeded client expectations.
These challenges underscored EPD’s ability to deliver high-quality, customized solutions under stringent timelines, reaffirming their position as a leader in electrical innovation.
Applications Beyond Fracking
While this project focused on fracking, mobile substations are versatile solutions with applications across various industries:
Disaster Relief
Providing emergency power during natural disasters ensures critical operations continue uninterrupted.
Temporary Power Needs
Supporting conventional drilling, seasonal power increases, or maintenance shutdowns.
Industrial Flexibility
Ideal for operations requiring portable, adaptable power solutions in remote or changing environments.
EPD’s mobile substations exemplify how customized electrical solutions can address diverse challenges, offering reliable and sustainable power wherever it’s needed.
Powering the Future of Energy Solutions
EPD’s customized mobile substation for e-fracking is a testament to their expertise in engineering innovative and sustainable electrical solutions. By addressing industry challenges and prioritizing safety, cost-effectiveness, and environmental responsibility, EPD has set a new standard for power management in fracking and beyond.
To learn more about EPD’s custom mobile substations and how they can support your operations, contact our team today. Let us design a solution tailored to your needs and drive your operations toward a sustainable future.
