Additive Pump Calibration Using Diverted Flow Feedback
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Solution Overview
Problem
Manual calibration of chemical pumps in hydraulic fracturing operations is time-consuming, prone to human error, and results in material waste due to subjective judgment of flow rates, leading to operational upsets and downtime.
Innovation Solution
A calibration system utilizing hardware and software to self-diagnose pump efficiencies, adjust flow rates automatically, and reduce waste by incorporating sensors and a diversion system to evaluate and adjust flow parameters, ensuring accurate additive delivery in real-time or during designated calibration modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual calibration is performed with operator judgment, then flexibility in operation is maintained, but time consumption and human error increase
Solution Approach 1:
The system performs self-calibration automatically using sensors and control algorithms without requiring operator intervention. The calibration process is executed autonomously by the system itself, eliminating manual time consumption while maintaining operational flexibility through programmable parameters.
Solution Approach 2:
Manual mechanical calibration operations are replaced with an automated electronic control system that uses sensors, processors, and actuators. This substitution eliminates human judgment and manual manipulation, reducing calibration time while maintaining or improving precision through consistent automated execution.
2Ease of operation
If manual calibration with subjective judgment is used, then operational simplicity is maintained, but measurement precision deteriorates
Solution Approach 1:
Subjective human judgment in flow rate measurement is replaced with objective electronic sensors and automated data processing. The system uses precise sensors to measure flow parameters and algorithms to calculate accurate calibration factors, eliminating the variability and inaccuracy of manual visual estimation.
Solution Approach 2:
The system implements closed-loop feedback where sensors continuously monitor flow rates and compare them against target values. Based on this feedback, the system automatically adjusts pump operations to achieve precise flow rates, ensuring measurement accuracy while maintaining operational simplicity through automated control.
3Reliability
If frequent manual calibration testing is performed, then pump accuracy is maintained, but material waste increases
Solution Approach 1:
Manual calibration testing that wastes material is replaced with automated precision control. The system uses sensors and algorithms to continuously monitor and adjust pump performance, maintaining accuracy without requiring frequent material-based testing. Calibration is performed using minimal or no material through electronic measurement and control.
Solution Approach 2:
Instead of discrete, material-consuming calibration tests, the system implements continuous monitoring and adjustment of pump accuracy. Sensors continuously track flow parameters and the control system makes real-time adjustments, maintaining pump accuracy continuously without periodic material waste associated with manual calibration cycles.
4Productivity
If automated calibration systems are implemented, then calibration precision and speed improve, but device complexity increases
Solution Approach 1:
The automated calibration system is designed to perform multiple functions including flow measurement, data processing, pump control, and error correction within a single integrated platform. This multi-functionality achieves high calibration speed and precision while minimizing the number of separate components needed, thereby reducing overall system complexity.
Solution Approach 2:
The system performs self-diagnosis and self-calibration using built-in sensors and algorithms, eliminating the need for external calibration equipment and expert operators. This self-sufficiency achieves rapid automated calibration while reducing system complexity by integrating all necessary functions into the existing pump structure without requiring additional complex external systems.
Data Source
AI summary
A pump control system includes an additive pump, the additive pump being fluidly coupled to a component of a hydraulic fracturing system. The system also includes an additive container, the additive container configured to provide an additive to the additive pump via a flow path. The system further includes a diversion system, arranged within the flow path between the additive pump and the component of the hydraulic fracturing system, the diversion system configured to redirected at least a portion of additive directed toward the component of the hydraulic fracturing system. The system includes a calibration system configured to receive the redirected portion of the additive, the calibration system adapted to adjust one or more operational parameters of the additive pump responsive to an evaluation of a flow parameter of the redirected portion of the additive.