Fluid Flow Normalizer for Reciprocating Pump Pulsation Control
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Solution Overview
Problem
In hydrocarbon recovery systems, reciprocating pumps generate pressure pulsations that can coincide with natural frequencies of downstream components, reducing the effectiveness of wellbore servicing and interfering with communication methods like mud pulse telemetry, and existing pulsation dampers are not easily adjustable in field environments.
Innovation Solution
A pumping system incorporating a fluid flow normalizer (FFN) with sensors to measure fluid flow characteristics and phase, and a feedforward active controller to adjust fluid flow by adding or removing fluid, thereby reducing repetitive variability in fluid flow output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reciprocating pumps are used to deliver fluid into a wellbore, then fluid delivery is achieved, but pressure pulsations are generated that interfere with downstream operations and communications
Solution Approach 1:
The system applies preliminary anti-action by using sensors to detect pressure pulsations before they propagate downstream and using active controllers to generate counteracting forces that cancel out the harmful pressure variations before they reach downstream components and communication systems
Solution Approach 2:
The patent introduces intermediary components including sensors that detect pressure pulsations and active controllers that mediate between the pump and downstream system, using control algorithms to generate compensating signals that eliminate harmful effects while preserving fluid delivery
2Stability of the object's composition
If pulsation dampers are used to dampen pressure pulsations, then pressure stability is improved, but the dampers are not easily adjustable in field environments
Solution Approach 1:
The system transitions from static, fixed-tuning pulsation dampers to dynamic active control where controllers continuously adjust their output based on real-time sensor feedback, allowing the system to adapt to changing operating conditions and be reconfigured in field environments without physical modification
Solution Approach 2:
The patent enables parameter changes by allowing the active controllers to modify control parameters such as gain, frequency response, and damping characteristics through software or electronic adjustment, providing adaptability and reconfigurability without changing the physical structure of the dampers
3Productivity
If pressure pulsations coincide with natural frequency of downstream components, then resonance occurs that reduces effectiveness of wellbore servicing
Solution Approach 1:
The system detects pressure pulsations and their frequency content using sensors and spectral analysis, then applies preliminary anti-action by generating counter-frequency signals that cancel resonant vibrations before they amplify and interfere with wellbore servicing operations
Solution Approach 2:
The patent implements feedback control where sensors continuously monitor pressure pulsations, the controller analyzes the frequency content to identify resonant conditions, and adjusts the control output in real-time to suppress resonance and maintain wellbore servicing effectiveness
4Loss of information
If pressure pulsations interfere with mud pulse telemetry, then communication through pumped fluid is disrupted
Solution Approach 1:
The system applies preliminary anti-action by detecting pressure pulsations that would interfere with mud pulse telemetry signals and generating compensating pressure variations that cancel the interference before it disrupts communication, preserving information transmission through the pumped fluid
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The FFN system effectively normalizes fluid flow characteristics, reducing pressure pulsations and noise, and enhancing the consistency of fluid delivery, which improves the effectiveness of wellbore servicing and communication through the pumped fluid.
Implementation Method 1
a first fluid flow normalizer (FFN) configured to at least one of add fluid to the output of the positive displacement pump and remove fluid from the output of the positive displacement pump
Data Source
AI summary
A pumping system is provided. The pumping system includes an output conduit, a first sensor, a second second sensor, a feedforward active controller, and a fluid flow normalizer (FFN). The output conduit is associated with an output of a positive displacement pump. The first sensor is configured to measure a fluid flow characteristic (FFC) within the output conduit. The second sensor is configured to measure a phase of the positive displacement pump. The feedforward active controller is configured to receive information related to the FFC, receive information related to the phase of the positive displacement pump, and determine an FFC variability value. The first fluid flow normalizer (FFN) is configured to at least one of add fluid to the output of the positive displacement pump and remove fluid from the output of the positive displacement pump in response to a signal from the feedforward active controller.