Recirculation Circuit for Hydraulic Fracturing Pump Pressure Control
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Solution Overview
Problem
Hydraulic fracturing fluid pumps face challenges in handling high pressures, leading to potential leaking or failure due to the difference in pressure containment capabilities between the suction and discharge sides, which can result in the suction side being unable to manage high-pressure fluid effectively.
Innovation Solution
A recirculation circuit with a control system that includes a control valve and a choke valve, controlled by a controller to manage differential pressures and flow velocities, directing high-pressure fluid back to the inlet of the pump, thereby reducing pressure and velocity to within safe limits for the pump components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high-pressure fluid is directed to the suction side of the fluid pump, then the pump can handle high pressures, but the suction side components may leak or fail due to insufficient pressure containment capability
Solution Approach 1:
The recirculation circuit acts as an intermediary system between the discharge side and suction side of the pump. High-pressure fluid from the discharge side is redirected through this circuit back to the suction side, serving as a protective mediator that prevents direct exposure of suction side components to high-pressure stress while maintaining system pressure handling capability
Solution Approach 2:
The control system performs preliminary action by monitoring differential pressure across the recirculation circuit and actuating the choke valve before high-pressure fluid reaches the suction side. This preventive measure ensures that pressure is reduced to safe levels prior to fluid entry, avoiding leakage and failure of suction side components
2Reliability
If the control valve is closed to prevent fluid flow through the recirculation circuit, then high-pressure fluid is contained, but the flow velocity through the control valve may exceed thresholds causing abrasive wear
Solution Approach 1:
The control system continuously monitors differential pressure across the recirculation circuit and uses this feedback to dynamically adjust the choke valve position. By maintaining differential pressure within a predetermined range, the system ensures flow velocity through the control valve remains below abrasive wear thresholds while still preventing high-pressure fluid from reaching the suction side
Solution Approach 2:
The choke valve dynamically changes the flow parameter (differential pressure) by adjusting its opening degree. This parameter modification ensures that when the control valve is closed, the flow velocity through it remains within safe limits, preventing abrasive wear while maintaining system reliability
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
This solution effectively reduces the risk of pump failure and extends the useful life of the pump and control valve by maintaining pressures and velocities below critical thresholds, preventing abrasive wear and damage.
Implementation Method 1
a recirculation circuit configured to direct fluid from the outlet of the fluid pump to the inlet of the fluid pump
Implementation Method 2
a control valve in the recirculation circuit... while the control valve is closed to prevent the fluid from flowing through the recirculation circuit
Implementation Method 3
a choke valve in the recirculation circuit... a differential pressure based on a first pressure of the fluid in the recirculation circuit upstream of the control valve and the choke valve and a second pressure of the fluid in the recirculation circuit downstream of the control valve and the choke valve
Data Source
AI summary
A control system may include a recirculation circuit configured to direct fluid from an outlet of a fluid pump, via a first portion of the recirculation circuit, to an inlet of the fluid pump via a second portion of the recirculation circuit. The control system may include a control valve and a choke valve in the recirculation circuit. The control system may include a controller configured to identify, based on a differential pressure that is based on a first pressure of the fluid in the first portion and a second pressure of the fluid in the second portion while the control valve is closed, a position for the choke valve that is to result in a flow velocity of the fluid through the control valve that is below a threshold, and configured to cause actuation of the choke valve in accordance with the position.