Fracturing Pump Fleet Balance Controller for Pressure Management
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Solution Overview
Problem
Current hydraulic fracturing processes face challenges in managing treating pressure accurately, especially during the initial stages, due to the need for manual adjustments by pump operators, and are limited in unconventional reservoirs by low rock permeability, leading to inefficient operation and increased costs.
Innovation Solution
A control system that includes processors, sensors, and a data interface to predict well pressure using models and adjust pumping rates automatically, ensuring pressure remains within safe thresholds by integrating real-time data from sensors and machine learning algorithms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual pressure management by pump operators is used, then the system is simpler to operate, but pressure control accuracy deteriorates especially during starting stages
Solution Approach 1:
The control system automatically adjusts pumping rates based on real-time pressure sensor data without requiring manual intervention. The system monitors treating pressure, compares it against target ranges, and autonomously modifies pump operations to maintain optimal pressure levels, enabling the system to self-regulate and eliminate dependency on operator skill and attention.
Solution Approach 2:
The system implements continuous feedback loops where pressure sensors monitor treating pressure in real-time, the controller receives this data, compares it against predetermined target ranges, and automatically adjusts pumping rates accordingly. This closed-loop control ensures accurate pressure maintenance by constantly responding to actual system conditions.
2Reliability
If automated pressure control systems are implemented, then pressure control accuracy improves, but device complexity increases
Solution Approach 1:
The control system autonomously manages pressure control operations by automatically interpreting sensor data, making control decisions, and adjusting pump operations without human intervention. This self-service capability enhances reliability by eliminating manual errors while the modular architecture keeps complexity manageable.
Solution Approach 2:
The system replaces manual mechanical pressure control with an automated control system that uses electronic sensors, processors, and communication interfaces. This substitution improves reliability through consistent automated operation while the use of standard electronic components and modular design prevents excessive complexity increase.
3Productivity
If real-time automated control is implemented, then operation efficiency improves, but initial system setup complexity increases
Solution Approach 1:
The system automatically executes pressure control operations in real-time without requiring continuous manual input or monitoring. Once configured, the system self-manages the entire pressure control process including data acquisition, analysis, decision-making, and actuation, thereby maximizing operational efficiency while requiring setup only once.
Solution Approach 2:
The control system operates continuously and automatically throughout the fracturing operation, maintaining optimal pressure control without interruption or manual intervention. This continuous automated operation maximizes productivity by eliminating downtime associated with manual adjustments while the system requires initial setup but operates autonomously thereafter.
Data Source
AI summary
A system can include one or more processors; memory; a data interface that receives data; a control interface that transmits control signals for control of pumps of a hydraulic fracturing operation; and one or more components that can include one or more of a modeling component that predicts pressure in a well fluidly coupled to at least one of the pumps, a pumping rate adjustment component that generates a pumping rate control signal for transmission via the control interface, a capacity component that estimates a real-time pumping capacity for each individual pump, and a control component that, for a target pumping rate for the pumps during the hydraulic fracturing operation, generates at least one of engine throttle and transmission gear settings for each of the individual pumps using an estimated real-time pumping capacity for each individual pump where the settings are transmissible via the control interface.