Automated Valve Control for Hydraulic Fracturing Pump Protection
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Solution Overview
Problem
Hydraulic fracturing systems face challenges in maintaining the flow of proppant-containing fluid to high-pressure pumps, leading to proppant falling out of solution and causing damage due to manual control delays and user errors, resulting in inefficiencies and pump damage.
Innovation Solution
An automated control system that determines a target flow rate and actuates valve apparatuses to maintain the proppant in solution by adjusting the flow rate, ensuring the proppant remains suspended and preventing damage to high-pressure pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual control of valves is used to supply fluid to high-pressure pumps, then operator flexibility is maintained, but responsiveness is slow and user errors occur leading to proppant settling and pump damage
Solution Approach 1:
The system uses automated control where the control system independently monitors flow rates and actuates valves without human intervention. Sensors detect flow rate deviations and the control system automatically adjusts valve positions to maintain target flow rates, eliminating manual operation errors and improving reliability.
Solution Approach 2:
The patent replaces manual mechanical valve control with an automated electromechanical system. Electronic sensors and control systems substitute for human operators, using electrical signals to actuate valves based on real-time flow rate measurements, thereby eliminating user error and improving responsiveness.
2Speed
If manual valve operation is used, then system simplicity is maintained, but responsiveness to unexpected flow rate changes is delayed causing proppant to fall out of solution
Solution Approach 1:
The system implements closed-loop feedback control where sensors continuously monitor actual flow rates and feed this information back to the control system. The control system compares actual flow rates with target flow rates and automatically adjusts valve positions to correct deviations, ensuring rapid response to flow rate changes while maintaining manageable system complexity through standardized control algorithms.
Solution Approach 2:
The control system is pre-programmed with target flow rates and control logic before operation begins. When flow rate deviations occur, the system immediately executes pre-planned corrective actions by actuating valves according to predetermined control strategies, eliminating delays associated with manual decision-making and response.
3Reliability
If flow rate falls below threshold, then energy consumption may be reduced, but proppant falls out of solution causing cavitation and pump damage
Solution Approach 1:
The control system continuously monitors flow rates and uses feedback control to maintain flow rates above the minimum threshold required to keep proppant in solution. When flow rates approach critical levels, the system automatically adjusts valve positions to increase flow, preventing proppant settling and pump damage while optimizing energy consumption by avoiding unnecessary high-flow operation.
Data Source
AI summary
A hydraulic fracturing system can include valve apparatuses that control the delivery of fluid to high-pressure pumps that supply the fluid to a wellhead. The valve apparatuses can receive electronic signals from a control system to regulate the flow rate of the fluid to the high-pressure pumps. In one or more examples, the flow rate of the fluid can be controlled such that proppant in the fluid remains in solution.