Automated Frack Pump Flow-Type Tracking for Component Life
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Solution Overview
Problem
Manually tracking the operation of frack pumps for clean and proppant laden fluid is tedious and prone to incorrect or missing data, affecting the maintenance and functionality of pump components.
Innovation Solution
An automated system to determine the flow type history of frack pumps based on proppant presence, using bulk modulus and sensors, and manage pump usage by comparing this history to pump models to adjust operations and parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual tracking of frack pump operation is used, then device complexity is reduced, but measurement precision and data accuracy deteriorate
Solution Approach 1:
The patent replaces manual mechanical tracking with an automated electronic monitoring system that uses sensors (such as acoustic emission sensors) to detect and record flow type. This substitution eliminates human error in data collection while maintaining relatively simple system architecture, thereby improving measurement precision without excessively increasing device complexity.
Solution Approach 2:
The monitoring system automatically detects, records, and analyzes flow type data without requiring manual intervention. The system self-manages the entire tracking process from data collection to generation of maintenance recommendations, improving accuracy while keeping operational complexity manageable through automation.
2Device complexity
If manual tracking of frack pump operation is used, then device complexity is reduced, but loss of time and productivity deteriorate
Solution Approach 1:
The system continuously monitors pump operation and provides real-time feedback about flow type conditions. This immediate feedback enables proactive maintenance scheduling based on actual pump usage patterns, reducing unplanned downtime while avoiding unnecessary maintenance interventions that would also cause downtime.
Solution Approach 2:
The system accumulates and analyzes flow type history data in advance to predict when maintenance will be needed. By performing preliminary analysis of pump usage patterns, the system allows maintenance to be scheduled at optimal times, reducing both planned and unplanned downtime while maintaining simple operational procedures.
3Device complexity
If manual tracking of frack pump operation is used, then device complexity is reduced, but reliability deteriorates
Solution Approach 1:
The patent replaces unreliable manual tracking with automated electronic monitoring that consistently records flow type data. This substitution eliminates human error and data loss, improving the reliability of maintenance decisions and thereby enhancing pump component reliability, while keeping the system architecture relatively simple.
Solution Approach 2:
The monitoring system automatically and consistently tracks pump operation without human intervention, ensuring complete and accurate data collection. This reliable automated tracking provides a solid foundation for maintenance decisions, improving component reliability while maintaining operational simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the efficiency and accuracy of pump maintenance by reducing downtime and costs through automated tracking and adaptive operation based on flow type history and pump models.
Implementation Method 1
A bulk modulus of the frack fluid can be used to determine the proppant presence
Data Source
AI summary
The life of internal components of a frack pump is affected by the frack fluid being pumped. The disclosure evaluates pump components and identifies parameters of frack pumps that may affect the remaining life of pump components based on pump models generated using flow type histories of the frack pumps. Pump related factors can also be used to identify the pump parameters. In one example, a method of evaluating pump components of a frack pump includes: (1) comparing a flow type history of the frack pump to at least one pump model, wherein the flow type history is automatically determined and is based on a proppant concentration of frack fluid pumped by the frack pump, (2) evaluating a condition of at least one component of the pump based on the comparing, and (3) changing a parameter of the pump based on the evaluating.