Hydraulic Fracturing Unit Profiles for Maximum Power Readiness
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Solution Overview
Problem
The operation of hydraulic fracturing equipment at a wellsite is complex and time-consuming due to the need for manual inspection and maintenance scheduling, leading to potential equipment breakdowns and reduced lifespan.
Innovation Solution
A supervisory controller system that monitors and assesses the health of hydraulic fracturing units, including pumps and engines, to determine maintenance needs and optimize operations by building profiles based on sensor data and historical information, allowing for efficient setup and maintenance scheduling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection and maintenance scheduling is used for hydraulic fracturing equipment, then equipment can be operated, but the operation becomes complex and time-consuming, leading to potential equipment breakdowns and reduced lifespan
Solution Approach 1:
The system enables self-service through automated health monitoring and maintenance scheduling. Sensors continuously collect equipment data, and the supervisory controller automatically analyzes this data to determine maintenance needs, eliminating the need for manual inspection and scheduling while improving operational efficiency
Solution Approach 2:
The system implements continuous feedback through sensors that monitor equipment health parameters in real-time. This feedback loop allows the supervisory controller to automatically adjust operations and schedule maintenance based on actual equipment condition, reducing both time loss and improving productivity
2Reliability
If manual inspection methods are used to determine maintenance schedules, then maintenance can be planned, but the process is inaccurate and time-consuming
Solution Approach 1:
The system replaces manual mechanical inspection with automated electronic sensing and data analysis. Sensors and the supervisory controller automatically monitor equipment health and determine maintenance schedules, eliminating manual inspection entirely while improving both accuracy and reducing time consumption
Solution Approach 2:
The supervisory controller acts as an intermediary between the equipment and maintenance scheduling process. It receives data from sensors, analyzes equipment health, and automatically determines maintenance schedules, providing accurate and timely maintenance planning without manual intervention
Data Source
AI summary
A methods and system to operate hydraulic fracturing units may include utilizing hydraulic fracturing unit profiles. The system may include hydraulic fracturing units may include various components. The components may include an engine and associated local controller and sensors, a transmission connected to the engine, transmission sensors, and a pump connected to the transmission and powered by the engine via the transmission and associated local controller and sensors. A supervisory controller may control the hydraulic fracturing units. The supervisory controller may be in communication with components of each hydraulic fracturing unit. The supervisory controller may include instructions to, for each hydraulic fracturing units, obtain hydraulic fracturing unit parameters, determine a hydraulic fracturing unit health assessment, and build a hydraulic unit profile including the health assessment and parameters. The supervisory controller may, based on the health assessment, determine the hydraulic fracturing unit's capability to be operated at a maximum power output.