Chemical Routing Control for Optimal Drilling Fluid Transfer Paths
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Solution Overview
Problem
Manual or semi-automatic routing of chemicals in drilling fluid plants is complex, time-consuming, and prone to errors, leading to contamination, equipment wear, downtime, and inefficiencies due to the need for skilled operators to optimize paths and manage equipment interactions.
Innovation Solution
An automated system using a graph model and graph search algorithms to find an optimum path for chemical transfers between sources and destinations, with a routing control unit communicating with a process control unit to control and monitor equipment, ensuring fault-tolerant and efficient chemical routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual or semi-automatic routing is used, then operator flexibility and equipment control are maintained, but routing complexity increases and error probability rises
Solution Approach 1:
The system performs self-routing by automatically determining optimal paths and controlling equipment without human intervention. The computer system autonomously plans transfer routes, selects equipment, and executes transfers based on real-time plant state feedback, eliminating manual routing operations while maintaining reliability.
Solution Approach 2:
The patent replaces manual mechanical routing operations with an automated computer-based control system. The mechanical decision-making process of operators is substituted with algorithmic path optimization and automated equipment control, reducing human error while maintaining operational flexibility.
2Productivity
If automated routing is implemented, then routing efficiency and accuracy improve, but system complexity increases
Solution Approach 1:
The computer system performs multiple functions including path optimization, equipment selection, transfer execution, and real-time monitoring within a single integrated platform. This multi-functional approach consolidates what would otherwise require separate complex subsystems, improving productivity while managing overall system complexity.
Solution Approach 2:
The system continuously monitors the actual plant state and uses this feedback to dynamically adjust routing decisions. Real-time feedback from sensors and equipment status allows the computer system to adapt to changing conditions, ensuring optimal performance without requiring overly complex predetermined control logic.
3Productivity
If multiple simultaneous transfers are coordinated manually, then throughput can be increased, but operator workload and error risk increase
Solution Approach 1:
The system autonomously coordinates multiple simultaneous transfers by independently planning and executing each transfer route while automatically resolving conflicts. The computer system manages the complexity of coordinating multiple transfers without requiring operator intervention, thereby increasing throughput while maintaining ease of operation.
Solution Approach 2:
The routing system dynamically adjusts transfer paths and timing based on real-time plant conditions and ongoing transfers. This dynamic coordination allows multiple transfers to proceed simultaneously with automatic conflict resolution, increasing throughput without overwhelming operators with coordination complexity.
4Device complexity
If fixed routing paths are used, then system simplicity is maintained, but adaptability to deviations and optimization opportunities is reduced
Solution Approach 1:
The system employs dynamic routing that adapts to changing plant conditions, equipment availability, and ongoing transfers. Rather than following fixed predetermined paths, the computer system continuously calculates optimal routes based on current state feedback, providing routing flexibility while managing complexity through algorithmic optimization.
Solution Approach 2:
The routing system changes operational parameters such as transfer paths, equipment selection, and transfer timing based on real-time plant conditions. This parameter adaptation allows the system to respond to deviations and optimize performance without requiring complex manual reconfiguration, balancing simplicity with flexibility.
Data Source
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AI summary
System for automatic routing of chemicals related to drilling fluids, the system comprising: • - a plurality of equipment, including a source (3) and a destination (5); • - one or more possible paths (PI, P2) between said source (3) and said destination (5); • - a process control unit (4) being adapted communicate with one or more of said plurality of equipment; and • - a routing control unit (2), the routing control unit being adapted to communicate with the process control unit (4), wherein said routing control unit (2) is provided with control algorithms for finding an optimum path (PI) between said source (3) and said destination (5) based at least partially on feedback from said process control unit (4).