Fracturing Pump Sequencing by Efficiency and Fuel Load
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Solution Overview
Problem
Fracturing systems for hydrocarbon extraction are inefficient, leading to high greenhouse gas emissions and fuel consumption due to the complexity of operating multiple pumps and equipment, which can result in operator errors and inefficiencies.
Innovation Solution
An automated hydraulic fracturing system using computer systems to control pump operations, optimizing efficiency scores, fuel usage, and equipment health monitoring, allowing for precise control and reduced manpower.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large suite of fracturing pumps and support equipment is used to perform fracturing tasks, then the fracturing treatment can be performed, but greenhouse gas emissions and fuel consumption increase due to system complexity
Solution Approach 1:
The system dynamically changes operational parameters by adjusting pump sequencing, ramp-up timing, and fuel type selection based on real-time efficiency scores. More efficient pumps are positioned closer to the blender and activated first, while less efficient pumps are positioned farther away and activated later, optimizing fuel consumption during the fracturing treatment.
2Power
If multiple fracturing pumps are operated simultaneously, then the required flow rate and pressure can be achieved, but operator errors and inefficiencies increase due to operational complexity
Solution Approach 1:
The control system automatically determines efficiency scores for each pump, ranks them, and sequences their activation without operator intervention. The system self-manages the complex coordination of multiple pumps, eliminating the need for operators to manually manage pump operations while achieving optimal treatment parameters.
Solution Approach 2:
The system continuously monitors pump performance and uses efficiency scores to dynamically adjust pump sequencing and operational parameters. This feedback mechanism ensures that the system adapts to changing conditions and maintains optimal operation throughout the fracturing treatment.
3Productivity
If pumps are positioned without optimization, then the pump array can be quickly assembled, but operational efficiency decreases due to suboptimal pump locations
Solution Approach 1:
The system assigns different roles and positions to pumps based on their individual efficiency characteristics. High-efficiency pumps are positioned closer to the blender and activated first, while lower-efficiency pumps are positioned farther away and activated later, creating a differentiated configuration that maximizes overall system efficiency.
Data Source
AI summary
A method including determining first and second pump efficiencies and ranking the first pump relative to the second pump based on the efficiencies and indicating that the first pump is more efficient that the second pump; positioning the first and second pumps in a pump array based on the efficiencies with more efficient pumps closer to either the blender or the wellhead; or ramping up the first and second pumps in order of the efficiencies. A method including ramping up a plurality of pumps to deliver a fluid to a wellhead at a treatment pressure and flow rate and switching a pump of the plurality of pumps to a second fuel at an ideal loading of the pump prior to the plurality of pumps supplying the fluid at the treatment pressure and flow rate.