Autonomous Hydraulic Fracturing Controller for Well Integrity
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Solution Overview
Problem
Hydraulic fracturing operations often require human operators to be present on site, posing safety risks and limiting response times due to the need for manual control of complex systems, which can lead to inefficiencies and safety issues.
Innovation Solution
A hydraulic fracturing system with a controller that monitors and controls various subsystems, including fracturing rigs, valves, and power sources, to maintain operating limits and prevent well integrity-related events, allowing for autonomous operation and remote management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If human operators manually control the hydraulic fracturing system, then the system can respond to changing conditions, but operator safety is at risk and response time is insufficient
Solution Approach 1:
The system enables autonomous operation where the hydraulic fracturing system monitors and controls itself through automated controllers that detect well conditions and adjust operational parameters without human intervention, eliminating safety risks to operators while maintaining rapid response capability
Solution Approach 2:
Manual mechanical control by operators is replaced with automated electronic control systems including controllers, sensors, and communication networks that monitor well conditions and adjust fracturing parameters automatically, providing both safety and rapid response
2Productivity
If multiple hydraulic fracturing rigs operate simultaneously to achieve high flow rates, then productivity increases, but system complexity and difficulty of monitoring increase
Solution Approach 1:
The controller system is designed to universally monitor and control multiple fracturing rigs, blending equipment, and well integrity systems through a unified platform that manages all subsystems simultaneously, enabling high productivity while reducing operational complexity
Solution Approach 2:
The system implements comprehensive feedback mechanisms where sensors continuously monitor pressure, flow rate, and well conditions across all rigs and equipment, with controllers automatically adjusting operations based on real-time data to maintain optimal productivity while managing system complexity
3Ease of operation
If human operators are present on site to control the system, then manual control is possible, but response time is limited due to human reaction delays
Solution Approach 1:
The system performs self-monitoring and self-control through automated controllers that continuously detect well conditions and immediately adjust operational parameters without human reaction delays, while maintaining the capability for human operators to intervene when needed
Solution Approach 2:
The automated system is pre-programmed with well integrity criteria and operational limits, enabling it to automatically detect and respond to changing conditions before they become critical, eliminating human reaction time delays while preserving manual control authority
Data Source
AI summary
A method may include monitoring an operation or a state of one or more subsystems of a hydraulic fracturing system. The hydraulic fracturing system may include one or more fracturing rigs, one or more blending equipment, and one or more power sources electrically connected to a first subset of the one or more fracturing rigs, or one or more fuel sources fluidly connected to a second subset of the one or more fracturing rigs. The hydraulic fracturing system may further include one or more missile valves, one or more zipper piping and zipper valve sets, one or more well head valves, and one or more well heads. The method may further include controlling, based on monitoring the operation or the state, the one or more subsystems within operating limits or based on operating expectations to cause or prevent an occurrence of one or more well integrity-related events.