Multi-rig Hydraulic Fracturing Pump Flow Distribution
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Solution Overview
Problem
Current hydraulic fracturing systems lack efficient and reliable distribution of pump flow among rigs, leading to suboptimal fuel consumption and component durability, which can result in premature equipment failure and reduced operational efficiency.
Innovation Solution
A hydraulic fracturing system with a controller that receives total pump flow and pressure requests, along with fuel consumption and component durability data, to optimize pump flow distribution among multiple rigs, using an optimization algorithm that balances fuel efficiency and component longevity by adjusting torque transfer through driveshafts and transmissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pump flow is distributed equally among all hydraulic fracturing rigs, then operational simplicity is maintained, but fuel consumption increases and component durability decreases
Solution Approach 1:
The system assigns different pump flow rates to different rigs based on their individual characteristics. The controller receives component durability data and fuel consumption data for each rig, then distributes pump flow non-uniformly - assigning higher flow rates to rigs with greater durability margins and lower flow rates to rigs with smaller margins, thereby optimizing overall fuel consumption while maintaining operational simplicity through automated control.
2Ease of operation
If pump flow is distributed equally among all hydraulic fracturing rigs, then operational simplicity is maintained, but component durability decreases
Solution Approach 1:
The system tailors pump flow distribution to each rig's specific component condition. The controller monitors component durability data for each individual rig and adjusts pump flow rates accordingly - rigs with healthier components receive higher flow rates, while rigs showing signs of wear receive reduced flow rates to extend their service life, all while maintaining automated operational simplicity.
3Loss of energy
If pump flow distribution is optimized based on fuel consumption data, then fuel efficiency improves, but system complexity increases
Solution Approach 1:
The system implements a feedback control mechanism where the controller continuously receives fuel consumption data and component durability data from each rig, processes this information to determine optimal pump flow distribution, and automatically adjusts the pump rates accordingly. This feedback loop optimizes fuel efficiency while managing system complexity through automated decision-making based on real-time data.
Solution Approach 2:
The system enables each rig to effectively 'self-regulate' its pump flow rate based on its own fuel consumption characteristics and component durability status. The controller autonomously determines the optimal operating parameters for each rig without requiring manual intervention, allowing the system to self-optimize fuel efficiency while managing complexity through distributed intelligence.
4Reliability
If pump flow distribution is optimized based on component durability data, then equipment lifespan extends, but system complexity increases
Solution Approach 1:
The system uses feedback control to continuously monitor component durability data from each rig and automatically adjust pump flow distribution to extend equipment lifespan. The controller processes durability information and implements appropriate flow rate adjustments, managing system complexity through automated decision-making while achieving extended equipment life.
Solution Approach 2:
Each rig effectively 'self-manages' its operational parameters based on its own component durability status. The controller autonomously determines optimal pump flow rates for each rig based on their specific durability characteristics, allowing the system to self-optimize equipment lifespan while managing complexity through distributed autonomous control.
Data Source
AI summary
A hydraulic fracturing system comprises a plurality of hydraulic fracturing rigs. Each hydraulic fracturing rig includes an engine, a transmission, and a hydraulic fracturing pump. A driveshaft is coupled between the transmission and the hydraulic fracturing pump to transfer torque from the engine to the hydraulic fracturing pump. The hydraulic fracturing system also includes a fuel consumption data for each hydraulic fracturing rig, and a controller. The controller is programmed to receive a total pump flow and pressure request, and identify a pump flow distribution for each hydraulic fracturing rig of the plurality of hydraulic fracturing rigs based on the total pump flow and pressure request and the fuel consumption data.