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 processes is prone to costly delays and safety hazards due to unpredictable exceptions, such as equipment failures or 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 using scripting languages to manage fracturing units, detect exceptions, and implement automated exception handling to maintain process efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual direction of fracturing fluid pumping sequences is used, then personnel can control the process, but costly delays and safety hazards occur due to unpredictable exceptions
Solution Approach 1:
The system enables automated self-service through exception handling scripts that automatically detect, diagnose, and correct equipment failures without human intervention. The managing application continuously monitors equipment status and executes pre-programmed remedial actions, allowing the system to service itself during operation and eliminate delays caused by manual response.
Solution Approach 2:
The system implements continuous feedback loops where sensors monitor equipment parameters in real-time, the managing application analyzes this data against expected ranges, and automated exception handling scripts execute corrective actions when deviations are detected. This closed-loop feedback mechanism ensures rapid response to exceptions, maintaining process safety and preventing delays.
2Productivity
If automated exception handling is implemented, then process efficiency and safety are maintained, but device complexity increases
Solution Approach 1:
The automated exception handling system is segmented into modular components: a managing application for coordination, individual exception handling scripts for specific equipment types, and sensor modules for monitoring. Each script is independent and handles specific exception types, allowing the complex system to be broken down into manageable, replaceable units that can be developed and maintained separately.
Solution Approach 2:
The managing application serves as an intermediary layer between the complex sensor network and the exception handling scripts. It receives data from multiple sensors, determines which exception script should execute, and coordinates the remedial actions. This intermediary simplifies the overall system architecture by providing a centralized control point that manages the complexity of automated exception handling.
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.