Automated FRAC Pad Valve Sequencing for Real-Time Monitoring
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Solution Overview
Problem
Conventional hydraulic fracturing systems rely heavily on human intervention, leading to potential human errors, inefficiencies, and increased non-productive time due to the lack of real-time monitoring and automated logging of valve phases and operational information.
Innovation Solution
An automated hydraulic fracturing system utilizing a computing system with sensors and a human machine interface (HMI) to automate valve sequencing, monitor equipment health, and provide real-time data logging, reducing human interaction and enhancing operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydraulic fracturing systems rely on human intervention to operate valves and monitor equipment, then operational flexibility and adaptability are maintained, but human errors increase and non-productive time increases
Solution Approach 1:
The system enables self-service operation through automated valve control and equipment monitoring. The computer system automatically sequences valve operations based on pre-programmed fracturing plans, and sensors continuously monitor equipment status without requiring constant human intervention. This self-acting mechanism reduces human errors while maintaining operational reliability.
Solution Approach 2:
The system implements continuous feedback loops where sensors monitor equipment health parameters and operational status in real-time, transmitting data to the computer system. The computer system processes this feedback information and automatically adjusts valve positions and monitoring parameters accordingly, ensuring reliable operation while minimizing non-productive time.
2Productivity
If manual monitoring and logging of valve phases and operational information are used, then system complexity is reduced, but real-time data availability and operational efficiency decrease
Solution Approach 1:
The system replaces manual mechanical monitoring and logging processes with automated electronic sensors and computer-based data management. Sensors automatically detect valve positions and operational parameters, while the computer system electronically logs and analyzes this data in real-time, significantly improving productivity without requiring excessive manual intervention.
Solution Approach 2:
The computer system serves as an intermediary between the physical fracturing equipment and the operators. It automatically collects data from sensors, processes operational information, and presents synthesized information to operators through the HMI, reducing the complexity of direct manual monitoring while enabling real-time decision-making.
3Loss of time
If automated valve sequencing and real-time monitoring are implemented, then non-productive time is reduced and operational insights are improved, but device complexity and initial system requirements increase
Solution Approach 1:
The system implements preliminary action by pre-programming fracturing plans with specific valve sequences and operational parameters before the fracturing operation begins. The computer system automatically executes these pre-planned sequences, eliminating delays associated with manual decision-making and reducing non-productive time during the actual fracturing process.
Solution Approach 2:
The computer system performs multiple functions including automated valve control, real-time data logging, equipment monitoring, and operational optimization. This multi-functionality consolidates what would otherwise require separate systems into a single integrated platform, managing system complexity while maximizing productivity benefits.
Data Source
AI summary
A system may include a built hydraulic fracturing system with a plurality of devices connected together and a simulation of the built hydraulic fracturing system on a software application. Additionally, a fracturing plan may be provided on the software application to include pre-made instructions to perform multiple processes in a hydraulic fracturing operation such as a sequence of valve operations to direct fluid flow through a selected path. Further, the fracturing plan may be modified to create a customized fracturing plan including the pre-made instructions and at least one modified instruction. Furthermore, the customized fracturing plan may be executed to perform at least one of the processes in the built hydraulic fracturing system.