Fluid Pump Ramp-Up Control via Pressure Monitoring
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Solution Overview
Problem
Hydraulic fracturing systems face challenges during the ramp-up period due to irregularities such as leaks or clogs, leading to abnormal pump operation and potential damage to the fluid pump.
Innovation Solution
A control system that includes a fluid pump, a motor, a variable frequency drive (VFD), and a controller. The controller monitors intake and discharge pressures and motor torque during ramp-up, detects irregularities by comparing these parameters to thresholds, and reduces motor torque via the VFD to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection of the hydraulic fracturing system is performed during ramp up, then operator awareness of system status is improved, but inspection efficiency is low and time consuming
Solution Approach 1:
The system performs self-diagnosis by automatically monitoring its own parameters (intake pressure, discharge pressure, torque) during ramp-up and detecting irregularities without requiring manual inspection. The controller continuously compares actual parameters against expected ranges and autonomously identifies abnormal conditions such as leaks, clogs, or obstructions.
Solution Approach 2:
The control system implements continuous feedback monitoring of pump operation parameters during ramp-up. Sensors measure intake pressure, discharge pressure, and motor torque, feeding this data back to the controller which compares it against threshold values to detect irregularities in real-time, enabling immediate response without manual intervention.
2Ease of operation
If ramp up is performed without monitoring, then operational simplicity is maintained, but abnormal operation causes excessive wear or damage to fluid pump
Solution Approach 1:
The control system implements continuous feedback monitoring of pump operation parameters during ramp-up. Sensors measure intake pressure, discharge pressure, and motor torque, feeding this data back to the controller which compares it against threshold values to detect irregularities in real-time, enabling immediate response without manual intervention.
Solution Approach 2:
The patent replaces manual mechanical inspection with an automated electronic control system that uses sensors and a controller to monitor pump operation parameters. This substitution eliminates the need for physical inspection while providing continuous, precise monitoring of intake pressure, discharge pressure, and torque to detect irregularities.
3Measurement precision
If continuous monitoring of all parameters is implemented, then detection accuracy is improved, but system complexity increases
Solution Approach 1:
The control system extracts and monitors only the three most critical parameters for detecting ramp-up irregularities: intake pressure, discharge pressure, and motor torque. By focusing on these specific parameters rather than all possible system variables, the system achieves high detection accuracy while maintaining manageable complexity. The controller compares these extracted parameters against predetermined threshold values to identify abnormalities.
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 control system effectively prevents excessive wear or damage to the fluid pump by detecting irregularities and reducing motor torque, thereby improving pump operation and extending its lifespan.
Implementation Method 1
a variable frequency drive (VFD) configured to control the motor
Implementation Method 2
monitor, during a ramp up period of the fluid pump, an intake pressure of the fluid pump, a discharge pressure of the fluid pump, and a torque of the motor
Data Source
AI summary
In some implementations, a controller may monitor, during a ramp up period of a fluid pump driven by a motor that is controlled by a variable frequency drive (VFD), an intake pressure of the fluid pump and a discharge pressure of the fluid pump. The controller may detect, based on monitoring the intake pressure and the discharge pressure, whether the intake pressure satisfies an intake pressure threshold or the discharge pressure satisfies a discharge pressure threshold. The controller may cause, via the VFD, reduction of a torque of the motor based on the intake pressure satisfying the intake pressure threshold or the discharge pressure satisfying the discharge pressure threshold.