Fracturing Fleet Pumping Sequence Control With Automated Exception Handling
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Solution Overview
Problem
Manual direction of fracturing fluid pumping sequences in hydraulic fracturing is prone to costly delays and safety hazards due to unpredictable exceptions, such as equipment failures and environmental changes, which can be challenging for inexperienced personnel to manage effectively.
Innovation Solution
An automated managing application controls the pumping sequence, retrieving instructions from a storage server and implementing automated exception handling to address deviations in equipment data, optimizing equipment selection and operation based on real-time sensor data and customer criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual direction of fracturing fluid pumping sequences is used, then equipment operation can be controlled, but costly delays and safety hazards occur due to unpredictable exceptions
Solution Approach 1:
The system performs preliminary actions by pre-programming pumping sequences and pre-identifying potential exceptions based on historical data and equipment specifications. Before actual pumping operations begin, the system prepares response protocols for anticipated exceptions, allowing rapid automated response when deviations occur, thereby reducing delays and maintaining safety without requiring manual intervention for every exception.
2Ease of operation
If manual direction of pumping sequences is used, then equipment control is possible, but inexperienced personnel cannot manage exceptions effectively
Solution Approach 1:
The system enables self-service by automating the exception handling process entirely. When an exception occurs during pumping operations, the system automatically detects the deviation, retrieves appropriate response instructions from pre-programmed protocols, and executes corrective actions without requiring human intervention. This eliminates the need for inexperienced personnel to manage exceptions while maintaining ease of operation through automated self-correction.
3Productivity
If automated managing application is used, then continuous operation is enabled through automated exception handling, but system complexity increases
Solution Approach 1:
The system replaces manual mechanical control with automated electronic control. A computer-based managing application substitutes for human operators, automatically monitoring pumping parameters, detecting exceptions, and executing corrective actions. This mechanical-to-electronic substitution enables continuous operation without human intervention while managing complexity through software automation rather than complex hardware systems.
4Loss of time
If automated exception handling is implemented, then delays are reduced, but equipment selection and operation optimization require sophisticated algorithms
Solution Approach 1:
The system implements feedback mechanisms where sensors continuously monitor pumping parameters and feed this data back to the managing application. When deviations from the pumping sequence are detected, the system automatically retrieves appropriate corrective instructions from pre-programmed protocols based on the type of exception detected. This feedback loop enables rapid exception response by automatically matching observed deviations with pre-prepared solutions, reducing response time without requiring complex real-time decision algorithms.
Data Source
AI summary
A method of controlling a pumping sequence of a fracturing fleet at a wellsite. A managing application executing on a computer in the control van can retrieve the pumping sequence from a local or remote storage computer. The managing application can establish an electronic communication link to receive sensor data from a plurality of fracturing units. The managing application can control the plurality of fracturing units with a stage script with multiple sequential instructions for a pumping stage of a pumping sequence while receiving one or more periodic data sets from the plurality of fracturing units wherein the data sets are indicative of the current state of the pumping stage of the pumping sequence.