Frac Pumping Control for Automated Valve Sequencing
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Solution Overview
Problem
Conventional hydraulic fracturing operations rely heavily on human intervention, leading to potential human errors, inefficiencies, and increased non-productive time due to the complex sequencing of valves and equipment in fracturing systems.
Innovation Solution
An automated hydraulic fracturing system with a computing system and sensors is introduced, which includes a software application for planning and executing continuous pumping operations, automating valve sequencing, and reducing human interaction through a human machine interface (HMI) for improved efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual valve sequencing and oversight are used in hydraulic fracturing operations, then human control and safety oversight are maintained, but operational time is increased and productivity is reduced
Solution Approach 1:
The system enables self-service automation where the control system automatically sequences valve operations and manages fluid flow without requiring continuous manual intervention. The automated control system monitors and adjusts operations based on pre-programmed parameters, allowing the hydraulic fracturing system to regulate itself and reducing the time spent on manual oversight.
Solution Approach 2:
The patent replaces manual mechanical valve operation with an automated control system that uses electronic signals to control valve sequencing. The control system substitutes human decision-making and manual valve handling with computer-generated commands, thereby eliminating the time loss associated with manual operations while maintaining operational safety.
2Reliability
If manual sequencing of valve operations is performed, then operational control is maintained, but the risk of human error increases
Solution Approach 1:
The control system incorporates feedback mechanisms that continuously monitor valve positions, fluid flow rates, and pressure parameters. This real-time feedback allows the system to detect and correct deviations from the planned sequence, ensuring operational safety while reducing the complexity of manual coordination. The feedback loop automatically adjusts operations based on actual system state, eliminating human error in sequencing.
Solution Approach 2:
The patent replaces manual valve sequencing with an automated electronic control system that manages valve operations through programmed logic. This substitution eliminates human error in sequencing while maintaining operational control, as the computer system follows precise pre-programmed instructions and can adapt to system conditions without human intervention.
3Productivity
If continuous pumping operations are implemented, then productivity is improved, but the complexity of coordinating multiple wells increases
Solution Approach 1:
The control system is designed with multi-functionality to handle multiple wells simultaneously. A single centralized control system can manage valve sequencing, fluid flow control, and coordination for multiple wellbores, eliminating the need for separate control systems for each well. This universal approach reduces overall system complexity while enabling continuous pumping operations across multiple wells.
Solution Approach 2:
The patent segments the control system into modular units that can independently manage individual wells while coordinating through a central controller. This segmentation allows complex multi-well operations to be broken down into manageable tasks, reducing the perceived complexity while maintaining the ability to perform continuous pumping operations across multiple wells simultaneously.
4Ease of manufacture
If automated valve sequencing is implemented, then operational costs are reduced, but the initial system complexity increases
Solution Approach 1:
The automated control system is designed to be self-regulating and self-monitoring, reducing the need for expensive manual labor and ongoing operational costs. The system automatically sequences valves, monitors parameters, and adjusts operations without requiring continuous human intervention, thereby reducing operational costs despite the initial investment in automation technology.
Solution Approach 2:
The patent replaces expensive manual operational labor with an automated electronic control system. While the initial system complexity increases due to the automation technology, the long-term operational costs are significantly reduced as the system can operate autonomously without requiring skilled manual intervention for valve sequencing and fluid flow management.
Data Source
AI summary
A system may have a built hydraulic fracturing system with a plurality of devices connected together and in fluid communication with one or more wells. The system may also include at least one continuous pumping operations for one or more wells and a fracturing pumping plan provided on a software application. The fracturing plan may include instructions to perform at least one continuous pumping operations for the one or more wells. The instructions may include a sequence of valve operations to direct fluid flow through a selected path into the one or more wells.