Frac Pump Flowrate Control for Smooth Diesel-Electric Transitions
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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 by modeling operating costs, shifting flowrates based on pump unit efficiency, and controlling transitions to minimize cost and ensure smooth flowrate changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple types of pumping equipment (diesel and electric frac pumps) are used in the fracturing fleet, then the versatility and operational flexibility are improved, but the operating costs increase due to varying fuel costs and power requirements
Solution Approach 1:
The system dynamically adjusts the flowrate allocation among pump units based on real-time operating conditions and efficiency characteristics. The control system continuously monitors and reconfigures which pumps operate and at what flowrates, transitioning from static to dynamic operation to optimize the mix of diesel and electric pumps during different stages of the fracturing process
Solution Approach 2:
The system changes operational parameters (flowrate distribution, pump activation/deactivation) based on the fracturing stage and efficiency data. By adjusting these parameters in real-time, the system optimizes the combination of pump types used, selecting electric pumps during efficient operating ranges and diesel pumps when conditions favor their operation, thereby reducing overall operating costs
2Productivity
If flowrate transitions are made quickly between pumping stages, then the productivity is improved, but flowrate dips occur causing operational delays and reduced reliability
Solution Approach 1:
The system performs preliminary actions by pre-calculating optimal interim flowrate setpoints before executing transitions. The control system prepares the pump configuration and flowrate distribution in advance, ensuring that transitions between pumping stages occur smoothly without dips or interruptions, thereby maintaining both productivity and reliability
Solution Approach 2:
The system uses feedback from flowrate sensors and pump performance data to continuously monitor the actual flowrate during transitions. This feedback loop allows the control system to adjust interim setpoints in real-time, preventing flowrate dips and ensuring stable transitions, thus resolving the contradiction between fast transitions and flowrate stability
3Ease of operation
If electric frac pumps operate outside their efficient flowrate range, then the ease of operation is improved, but the energy efficiency decreases leading to higher operating costs
Solution Approach 1:
The system replaces manual pump selection and flowrate adjustment with an automated control system that uses efficiency data and real-time conditions to optimize pump operation. This substitution of mechanical/manual control with intelligent automation maintains ease of operation while dramatically improving energy efficiency by keeping electric pumps within their optimal flowrate ranges
Solution Approach 2:
The control system performs self-service by automatically monitoring pump performance, identifying inefficient operations, and adjusting flowrate allocations to optimize efficiency. The system serves itself by making real-time decisions about pump configuration without requiring manual intervention, thereby maintaining operational simplicity while maximizing energy efficiency
Data Source
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 smooth the flowrate transition to an operational setpoint with a higher flowrate. An optimization process communicatively connected to the plurality of pumping units can iterate an interim setpoint with a transfer function model to each pumping unit. The transfer function model can generate a smooth flowrate transition by decreasing the flowrate of at least one pump unit while increasing the flowrate to the remaining pump units.