Active Accumulator Feedback Control for Pump Cavitation
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Solution Overview
Problem
Standard passive or fixed accumulators in wellbore servicing systems struggle to maintain optimal charge pressures or volumes due to variations in flowrates and line lengths, leading to resonance issues and cavitation, which degrade pump performance and shorten equipment life.
Innovation Solution
An active accumulator system that automatically adjusts charge pressure or volume based on real-time feedback from suction header pressure and cavitation detectors, using a controller to regulate gas addition or withdrawal to maintain optimal conditions and minimize cavitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If passive or fixed accumulators are used with displacement pumps, then the system structure is simple, but the accumulator cannot maintain optimal charge pressure or volume when flowrates and line lengths vary
Solution Approach 1:
The patent transforms the static, fixed charge pressure accumulator into a dynamic system where the charge pressure can be automatically adjusted in real-time based on actual operating conditions. The controller continuously monitors pump suction pressure and cavitation conditions, then regulates the charge pressure of the accumulator accordingly, allowing the system to adapt to varying flowrates and line lengths without manual intervention.
Solution Approach 2:
The patent implements a feedback control system where the accumulator's charge pressure is regulated based on real-time monitoring of pump suction pressure and cavitation detection. The controller receives feedback signals from pressure sensors and cavitation detectors, processes this information, and automatically adjusts the accumulator charge pressure to maintain optimal operating conditions, eliminating the need for manual adjustment.
2Reliability
If fixed accumulators are adjusted based on expected flowrate before a job, then initial setup is simple, but performance degrades as pump characteristics change during operation
Solution Approach 1:
The patent implements a feedback control system where the accumulator's charge pressure is regulated based on real-time monitoring of pump suction pressure and cavitation detection. The controller receives feedback signals from pressure sensors and cavitation detectors, processes this information, and automatically adjusts the accumulator charge pressure to maintain optimal operating conditions, eliminating the need for manual adjustment.
Solution Approach 2:
The system enables the accumulator to self-regulate its charge pressure automatically based on real-time pump operating conditions. The controller continuously monitors suction pressure and cavitation signals, then autonomously adjusts the charge pressure without requiring external intervention, allowing the system to maintain optimal performance throughout the entire operation.
3Reliability
If charge pressure is increased to prevent cavitation, then pump reliability improves, but resonance may occur in the suction header at certain flowrates
Solution Approach 1:
The patent implements a feedback control system where the accumulator's charge pressure is regulated based on real-time monitoring of pump suction pressure and cavitation detection. The controller receives feedback signals from pressure sensors and cavitation detectors, processes this information, and automatically adjusts the accumulator charge pressure to maintain optimal operating conditions, eliminating the need for manual adjustment.
Solution Approach 2:
The patent dynamically changes the charge pressure parameter of the accumulator based on real-time operating conditions. Rather than using a fixed high charge pressure that may cause resonance, the system continuously adjusts the charge pressure to the minimum level needed to prevent cavitation at each moment, thereby avoiding resonance conditions while maintaining pump reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The active accumulator system ensures optimal pump operation by maintaining optimal charge pressures and volumes, reducing cavitation and extending equipment life while adapting to changing flowrates and rig-up conditions.
Implementation Method 1
an accumulator operable to store a charge fluid
Implementation Method 2
a cavitation detector operable to monitor a cavitation condition of the pump
Data Source
AI summary
An active accumulator system which automatically adjusts or adapts the charge pressure or volume of an accumulator to maintain an optimal charge pressure or volume of the accumulator may provide optimal operation of a pump. An active accumulator system may comprise a flow line coupled to a pump, wherein a fluid flows through the flow line to the pump, an accumulator coupled to the flow line, a transducer coupled to the pump, wherein the transducer detects a parameter of the pump at an inlet of the pump, and a controller coupled to the transducer and the accumulator, wherein the controller receives the parameter, and wherein the controller regulates air flow to the accumulator such that the accumulator is adjusted to an optimal charge pressure based at least in part on the parameter.