Frac Pump Control Interface for Real-Time Pressure Optimization
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Solution Overview
Problem
Current methods of controlling fracturing pumps in hydraulic fracturing systems rely heavily on operator skill, leading to errors, inefficiencies, and safety risks due to manual adjustments, and lack real-time automation for precise control and optimization.
Innovation Solution
An automated hydraulic fracturing system utilizing software and computer systems to control frac pump operations, integrating data from various equipment sources, performing rate and pressure optimization, and implementing algorithm-based recommendations for precise control, reducing operator intervention and enhancing safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operator control is used for fracturing pumps, then ease of operation is maintained, but reliability deteriorates due to operator errors and lack of precision
Solution Approach 1:
The system continuously monitors pump performance parameters (flow rate, pressure, horsepower) and compares them against target values, automatically adjusting pump settings based on real-time feedback to maintain reliable operation
Solution Approach 2:
The control system autonomously manages pump operations by automatically adjusting settings, monitoring performance, and making corrections without requiring constant operator intervention, thereby improving reliability while maintaining ease of operation
2Productivity
If manual pump adjustments are made, then operational flexibility is maintained, but productivity deteriorates due to inefficiencies and delays
Solution Approach 1:
The system pre-sets target values for pump performance parameters and automated adjustments based on fracturing stage requirements, enabling efficient operation through pre-planned control strategies
Solution Approach 2:
Manual mechanical adjustments are replaced with an automated electronic control system that uses software algorithms to optimize pump operations, increasing productivity while managing complexity through digitalization
3Manufacturing precision
If real-time automated control is implemented, then manufacturing precision (control precision) is improved, but device complexity increases
Solution Approach 1:
The control system performs multiple functions including real-time monitoring, automated adjustments, performance tracking, and data logging within a single integrated platform, achieving high precision without proportionally increasing complexity
Solution Approach 2:
A centralized control computer acts as an intermediary between the pumps and the operator, managing complex automated control logic and presenting simplified interfaces that hide system complexity while delivering precise control
4Loss of energy
If automated pump control is used, then loss of energy is reduced through optimization, but use of energy by moving object increases due to continuous monitoring and control
Solution Approach 1:
The system monitors actual pump energy consumption and compares it to target values, automatically adjusting operations to optimize energy efficiency and reduce waste
Solution Approach 2:
The control system dynamically adjusts pump operating parameters such as speed, pressure, and flow rate based on real-time conditions and target values, optimizing energy efficiency by changing parameters rather than maintaining fixed high-energy operation
Data Source
AI summary
In a general aspect, the present disclosure relates to techniques for providing a pumping control user interface used to control an automated hydraulic fracturing system. In some embodiments, a system displays a pumping control interface associated with a plurality of fracturing pumps. The system receives first input for a target input region. After receiving the first input, the system causes a hydraulic fracturing system to perform a hydraulic fracturing operation. While the hydraulic fracturing operation is being performed, the system displays an operation recommendation that includes displaying a suggested change to an operating setting. The system receives second input corresponding to acceptance of the operation recommendation and, in response, causes the hydraulic fracturing system to implement the operation recommendation and continue performing the hydraulic fracturing operation.