Hydraulic Fracturing Flow Ramp Control for Pressure Stability
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Solution Overview
Problem
Hydraulic fracturing operations face challenges in efficiently and effectively controlling the output of numerous hydraulic fracturing units due to their complexity, leading to potential equipment damage and operational inefficiencies from uncontrolled events like well screen-out or over-pressure conditions.
Innovation Solution
Implementing semi- or fully-autonomous systems and methods that utilize a supervisory controller to manage hydraulic fracturing units, receiving rate ramp signals and operational parameters to control flow rates and pressures, ensuring controlled increases and maintaining target flow rates and pressures through a controlled increasing flow rate schedule.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual control methods are used for hydraulic fracturing units, then operational flexibility is maintained, but equipment damage and operational inefficiencies occur due to uncontrolled events
Solution Approach 1:
The supervisory controller automatically monitors and adjusts the operation of multiple hydraulic fracturing units without continuous manual intervention. The system self-regulates flow rates and pressures by receiving rate ramp signals and automatically implementing controlled increasing flow rate schedules, allowing the system to serve itself and prevent uncontrolled events.
Solution Approach 2:
The supervisory controller continuously receives operational data from sensors monitoring flow rates, pressures, and unit status. This feedback loop enables the controller to detect deviations from target parameters and automatically adjust unit operations to maintain safe and efficient fracturing conditions, preventing equipment damage from uncontrolled events.
2Productivity
If multiple hydraulic fracturing units operate simultaneously, then productivity increases, but control complexity and difficulty of coordination increase
Solution Approach 1:
The patent combines multiple hydraulic fracturing units under a single supervisory controller that coordinates their operations. By merging the control functions for multiple units into one centralized system, the patent manages the complexity of coordinating numerous units while maintaining high productivity through synchronized operation and unified monitoring.
Solution Approach 2:
The supervisory controller is designed as a universal system capable of managing multiple different hydraulic fracturing units simultaneously. It performs multiple functions including monitoring flow rates, regulating pressures, coordinating unit startup and shutdown, and responding to various operational conditions, thereby simplifying the control of complex multi-unit operations.
3Productivity
If flow rate increases are made rapidly to meet target rates, then productivity is improved, but equipment damage risk increases due to uncontrolled events
Solution Approach 1:
The supervisory controller implements preliminary action by receiving rate ramp signals that define the desired flow rate profile before actual fracturing begins. It pre-calculates and prepares controlled increasing flow rate schedules that gradually ramp up unit outputs to target rates, preventing sudden pressure spikes and equipment damage while still achieving productivity goals.
Solution Approach 2:
The system dynamically adjusts the flow rate increase profile based on real-time conditions. Rather than using fixed rigid schedules, the supervisory controller continuously monitors unit responses and modifies the rate of increase to balance productivity gains with equipment protection, allowing flexible adaptation to changing operational conditions during the fracturing process.
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 operational efficiency by preventing equipment damage and reducing delays through prompt, controlled adjustments in hydraulic fracturing unit outputs, ensuring safe and efficient fracturing operations.
Implementation Method 1
slurry may be pumped, via hydraulic fracturing pumps, under high pressure to perforations, fractures, pores, faults, or other spaces in the reservoir rocks or formations
Implementation Method 2
As the pressure of the slurry builds, the reservoir rocks or formation may fail and begin to fracture further
Implementation Method 3
receiving rate ramp signals and operational parameters associated with pumping fracturing fluid into a wellhead. The one or more operational parameters may include one or more of a target flow rate, a maximum flow rate, a target pressure, or a pressure range
Implementation Method 4
increasing a flow rate from the at least some of the hydraulic fracturing units according to a controlled increasing flow rate schedule toward the one or more of the target flow rate or the target pressure
Implementation Method 5
As the slurry is removed, proppants in the slurry may be left behind and may 'prop' or keep open the newly formed fractures
Implementation Method 6
proppants in the slurry may be left behind and may 'prop' or keep open the newly formed fractures, thus preventing the newly formed fractures from closing
Data Source
AI summary
Systems and methods for operating hydraulic fracturing units to pump fracturing fluid into a wellhead may include receiving a target flow rate and/or a target pressure for fracturing fluid supplied to the wellhead. The systems and methods may increase a flow rate from the hydraulic fracturing units according to a controlled increasing flow rate schedule toward the target flow rate and/or target pressure. When it has been determined the target flow rate and/or target pressure has been achieved, the systems and methods also may include operating the hydraulic fracturing units to maintain the target flow rate and/or target pressure. When the target flow rate has not been achieved, the systems and methods also may include generating notification signals, and/or when the target pressure has not been achieved, the systems and methods further may include operating the hydraulic fracturing units to maintain a maximum flow rate.