Hydraulic Fracturing Fleet Cost Optimization via Flowrate Allocation

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Solution Overview

Problem

The hydraulic fracturing process faces challenges in optimizing the performance of fracturing fleets comprising multiple types of pumping equipment, leading to inefficiencies, delayed transitions, and higher operating costs due to fuel costs and varying power requirements of diesel and electric frac pumps.

Innovation Solution

An optimization process executing on a computer system within a data van communicatively connected to the fracturing fleet directs the pumping operation of multiple pump units. This process models the operating cost of diesel and electric pumping groups, shifts flowrate between pump units based on operational characteristics, and iteratively adjusts flowrates for smooth transitions, thereby optimizing the fracturing fleet's performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple types of pumping equipment (diesel and electric frac pumps) are used in the fracturing fleet, then pumping capacity and versatility are improved, but operating costs increase due to varying fuel costs and power requirements

Engineering Contradiction:

Improvepumping capacityVSAvoidoperating cost

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The system dynamically adjusts the operational status of pump units by receiving current operational data, determining optimal transitions between active and inactive states, and generating control signals in real-time based on changing flowrate requirements and cost considerations

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system continuously receives operational data from pump units including flowrate, pressure, and status information, processes this feedback to determine optimal pump configurations, and adjusts pump unit operations accordingly to minimize operating costs while maintaining required performance

Inventive Principle:

Principle #23Feedback

2Productivity

If flowrate is increased to meet fracturing requirements, then production stimulation is improved, but pumping inefficiencies and operating costs increase

Engineering Contradiction:

ImproveflowrateVSAvoidpumping inefficiency

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The system determines optimal subsets of pump units to activate based on current flowrate requirements, avoiding the inefficiency of running all available pumps at partial capacity by selectively engaging only the necessary number of pump units

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system changes operational parameters by adjusting which pump units are active versus inactive, and modifies flowrate distribution among active units to optimize the balance between meeting production requirements and minimizing energy loss

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If pump units are rapidly switched between active and inactive states to optimize costs, then operating cost reduction is achieved, but system stability and smooth operation deteriorate

Engineering Contradiction:

Improveoperating costVSAvoidsystem stability

Core Design Contradiction:

Use of energy by moving objectVSStability of the object's composition

Solution Approach 1:

The system performs preliminary evaluation of transition feasibility by assessing current operational state and predicted future requirements before executing pump unit status changes, ensuring that transitions are made at appropriate times to maintain stability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically evaluates transition opportunities in real-time, adjusting pump unit configurations responsively while monitoring system stability, allowing cost optimization through flexible pump management without compromising operational smoothness

Inventive Principle:

Principle #15Dynamics

4Adaptability or versatility

If the number of pump units is increased to meet variable flowrate demands, then adaptability to different fracturing scenarios is improved, but device complexity and management difficulty increase

Engineering Contradiction:

Improveflowrate flexibilityVSAvoidfleet complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system provides self-service by automatically receiving operational data from multiple pump units, independently determining optimal pump configurations and transitions, and generating control signals without requiring complex manual coordination, thereby simplifying the management of the fracturing fleet

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12281555B2Method to optimize hydraulic fracturing spread with electric pumps

Publication Date: 2025.04.22 HALLIBURTON ENERGY SERVICES INC

AI summary

A method of controlling a pumping stage of a fracturing fleet at a wellsite with a set of diesel pumps and at least one electric pump to reduce the total operating cost by decreasing the flowrate to the pump units with the higher operating cost and increasing the flowrate to the pump units with the lower operating costs. An optimization process on a computer system communicatively connected to the plurality of pumping units can communicate a first interim setpoint to each pumping unit. The optimization process can calculate an operating cost for the diesel frac pumps based on sensor measurements of pressure, flowrate, and motor speed. The optimization process can calculate an operating cost for the electric frac pumps based on the measured power usage and cost of the power. The optimization process can lower the operating cost of fracturing fleet below a threshold operating cost value.