FPGA Controller for Pump Health Monitoring via Frequency Domain Analysis
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Solution Overview
Problem
Current pump monitoring systems in hydraulic fracturing operations primarily collect and analyze low-frequency data, missing the opportunity to utilize high-frequency data from pressure sensors for more accurate health monitoring, which can lead to inefficient operation or component failure.
Innovation Solution
A system utilizing a field-programmable gate array (FPGA) controller to collect high-frequency data from sensors, perform frequency domain analysis, and convert it into low-frequency data for transmission to a monitor, enhancing the accuracy of pump health monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high frequency data is collected from sensors, then measurement precision is improved, but device complexity increases due to the need for FPGA controller and frequency domain analysis
Solution Approach 1:
An FPGA controller is introduced as an intermediary device between the pressure sensors and the monitoring system. The FPGA performs frequency domain analysis on high frequency sensor data and converts it to low frequency data, enabling accurate pump health monitoring without requiring the main monitoring system to directly process complex high frequency signals.
Solution Approach 2:
The patent replaces traditional mechanical signal processing methods with electronic/FPGA-based frequency domain analysis. Instead of using complex mechanical filtering or direct high-frequency processing in the monitoring system, the solution uses an FPGA to electronically transform high-frequency data into low-frequency data that can be easily processed by standard monitoring equipment.
2Loss of information
If high frequency data is processed and transmitted, then information completeness is improved, but loss of time increases due to data processing requirements
Solution Approach 1:
The FPGA controller performs frequency domain analysis and data conversion in advance, before the data reaches the main monitoring system. By pre-processing high frequency data into low frequency data at the source, the system preserves complete health information while eliminating time-consuming processing steps at the remote monitoring location.
Solution Approach 2:
The data processing function is segmented into two parts: frequency domain analysis and conversion performed by the FPGA controller at the pump location, and final monitoring and analysis performed by the remote monitoring system. This segmentation allows high frequency data to be processed locally in real-time while enabling comprehensive remote monitoring without overwhelming the central system.
3Device complexity
If low frequency data is collected using traditional controllers, then device complexity is reduced, but measurement precision deteriorates due to inability to capture high frequency pump conditions
Solution Approach 1:
The patent changes the frequency parameter of the collected data from high frequency to low frequency through FPGA-based frequency domain analysis. Pressure sensors capable of high frequency measurement are used, but the FPGA transforms this high frequency data into low frequency data that maintains pump health information while being compatible with simpler monitoring systems.
Data Source
AI summary
A system for monitoring a pump, while the pump operates at a worksite, is disclosed. The system includes one or more sensors, wherein each of the one or more sensors is associated with the pump and is configured to collect high frequency data associated with the pump. The system further includes a field-programmable gate array (FPGA) controller configured to receive the high frequency data from the one or more sensors and is also configured to generate low frequency data based on the high frequency data. The system further includes a low frequency controller configured to receive the low frequency data from the FPGA controller and configured to transmit the low frequency data to a monitor.