Fracturing Pump Control System for Manifold Connection Accuracy
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Solution Overview
Problem
Hydraulic fracturing operations face challenges in accurately connecting fracturing pumps to manifold systems, leading to miscommunication and potential over-pressurization or unintended exposure of pressurized fluid, due to manual handling and lack of automated valve control.
Innovation Solution
A control system is introduced that includes a low pressure manifold, a high pressure manifold, a pump, and a valve, with a processor to determine fluid communication and control the valve and pump, automating the pairing of pumps and valves and defining flow paths to prevent miscommunication and ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling and lack of automated valve control are used, then device complexity is reduced, but reliability deteriorates due to miscommunication and potential over-pressurization
Solution Approach 1:
The system uses sensors to automatically detect pump connections to manifold outlets and uses this information to autonomously control valve positions, eliminating the need for manual intervention and improving connection accuracy without proportionally increasing complexity
Solution Approach 2:
Manual mechanical valve handling is replaced with an automated control system that uses sensors to detect fluid communication and electronically controls valve actuation, improving reliability by eliminating human error in the valve control process
2Reliability
If automated valve control is implemented, then reliability improves by preventing over-pressurization, but device complexity increases due to control system requirements
Solution Approach 1:
Sensors provide real-time feedback on pump connection status to the control system, which automatically adjusts valve positions accordingly, ensuring safe operation by preventing over-pressurization while maintaining a relatively simple control architecture
Solution Approach 2:
The control system automatically determines valve positions based on sensor data about pump connections, eliminating manual intervention and improving safety without requiring complex external control mechanisms
3Productivity
If manual valve control is used, then ease of operation is maintained, but productivity deteriorates due to miscommunication and operational delays
Solution Approach 1:
Manual valve control is replaced with automated electronic control based on sensor input, improving operational efficiency by eliminating miscommunication and delays while maintaining ease of operation through automatic system response
Solution Approach 2:
The system automatically detects pump connections and controls valves without manual intervention, improving productivity by eliminating operational delays while keeping the interface simple and intuitive
Data Source
AI summary
A system can include a low pressure manifold that includes an inlet and a plurality of outlets and a high pressure manifold that comprises a plurality of inlets and an outlet. The system can include a flow path that comprises one of the outlets of the low pressure manifold and one of the inlets of the high pressure manifold. The system can further include a pump that includes a portion of the flow path and a valve coupled with one of the low pressure manifold and the high pressure manifold. The system can further include a control system coupled with the valve and the pump, and the control system can include a processor that is configured to make a determination of whether the valve is in fluid communication with the flow path and control at least one of the valve and the pump based on the determination.