Dual-Pump Clutch Control for Hydraulic Fracturing Downtime Reduction
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Solution Overview
Problem
In dual-pump single-power source hydraulic fracturing systems, shutting down one pump to address issues leads to unnecessary downtime for all pumps due to the shared power source, as the system requires all pumps to be stopped when a problem occurs, even if only one is faulty.
Innovation Solution
Implementing a controller that monitors measurement values such as clutch speed and crank angles to disengage the mechanical connection between the power source and the faulty pump while keeping the other pump operational, allowing for selective shutdown and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single power source powers multiple pumps to improve flow capacity and efficiency, then the flow capacity and efficiency are improved, but if a problem occurs with one pump, all pumps must be shut down resulting in increased downtime
Solution Approach 1:
The patent divides the mechanical connection between the power source and each pump into separate controllable segments using clutches. Each clutch can independently engage or disengage the connection between the power source and a specific pump, allowing one pump to be isolated and shut down without affecting the operation of other pumps connected to the same power source.
Solution Approach 2:
The patent introduces clutches as intermediary components between the power source and the pumps. These clutches act as mediators that can selectively transmit or block mechanical power from the power source to individual pumps, enabling independent control of each pump's connection to the power source and allowing selective shutdown of faulty pumps while maintaining operation of healthy pumps.
2Reliability
If the power source is shut down to address a problem with one pump, then the problem can be addressed, but all pumps including operational ones must be stopped
Solution Approach 1:
The patent segments the power transmission path into independent controllable connections for each pump through the use of clutches. This allows the system to isolate and address problems with one pump by disengaging its clutch, while maintaining power transmission and operational status of other pumps with engaged clutches, thereby preserving overall system reliability and productivity.
Solution Approach 2:
The clutches serve as intermediary components that enable selective disconnection of individual pumps from the power source without shutting down the power source itself. This intermediary mechanism allows operators to address problems with one pump while keeping the power source running and other pumps operational, thus maintaining both system reliability and operational efficiency.
3Power
If a mechanical connection is used between the power source and pumps, then power transmission is reliable, but the connection cannot be selectively disengaged for individual pumps
Solution Approach 1:
The patent transforms the static mechanical connection between the power source and pumps into a dynamic, selectively controllable connection using clutches. Each clutch can be engaged or disengaged based on operational requirements, allowing the system to adaptively control power transmission to individual pumps. This dynamic capability enables selective shutdown of specific pumps while maintaining power transmission to others, providing both reliable power transmission and operational flexibility.
Solution Approach 2:
The clutches act as intermediary components inserted between the power source and each pump, transforming the direct mechanical connection into a controllable indirect connection. These intermediaries can selectively transmit or block power flow, providing the system with adaptability to engage or disengage individual pump connections as needed while maintaining reliable power transmission when engaged.
Data Source
AI summary
In some implementations, a controller may obtain a set of measurement values associated with the dual-pump single-power source system, wherein the set of measurement values includes at least one of one or more speed measurements associated with a clutch that is coupled to a power source and a first pump of the dual-pump single-power source system, a measurement value indicating an output speed of the power source, or a first crank angle associated with the first pump and a second crank angle associated with a second pump of the dual-pump single-power source system. The controller may detect that the clutch is experiencing slippage based on comparing at least two measurement values of the set of measurement values. The controller may perform an action to cause the clutch to disengage a mechanical connection between the first pump and the power source while the power source is running and is mechanically connected to the second pump.