Fracturing Pump Throttling for Stable Flow During Transitions

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Solution Overview

Problem

In fracturing operations, the abrupt power changes of pumps in multi-pump systems cause undesirable variations in the total flow rate, making it difficult to maintain a consistent flow within narrow limits, especially when pumps are powered on and off.

Innovation Solution

Implementing a system and method to throttle the decrease or increase in pump flow rates dynamically to maintain a relatively constant total flow rate by gradually reducing power to one pump while another is powered on, adjusting the rates based on the counteracting forces and momentum changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If pumps are powered on and off abruptly in a multi-pump system, then pump responsiveness and operational flexibility are improved, but total flow rate stability deteriorates

Engineering Contradiction:

Improvepump operational flexibilityVSAvoidtotal flow rate stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The system pre-calculates and implements throttling actions before pump power changes occur. When a pump is about to be powered on or off, the controller proactively adjusts the throttle position to compensate for the impending flow change, ensuring smooth transitions and maintaining stable total flow rate throughout the transition period.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors the actual flow rate of each pump and the total flow rate, comparing these values against target parameters. Based on this feedback, the controller dynamically adjusts throttle positions to maintain flow rate stability during pump transitions, correcting deviations in real-time.

Inventive Principle:

Principle #23Feedback

2Speed

If pump power is changed abruptly, then system response time is reduced, but flow rate variation exceeds acceptable limits

Engineering Contradiction:

Improvesystem response speedVSAvoidflow rate control precision

Core Design Contradiction:

SpeedVSManufacturing precision

Solution Approach 1:

The system dynamically adjusts the throttling rate based on the pump's operational state and the required flow rate changes. During pump transition, the throttle position is modified at variable rates to match the pump's acceleration or deceleration characteristics, enabling rapid response while maintaining precision within acceptable flow rate limits.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the throttle parameter (throttle position) in a controlled manner during pump transitions. By adjusting the throttle opening degree as a variable parameter rather than holding it fixed, the system enables smooth flow rate transitions that accommodate both rapid response requirements and precision control limits.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of stationary object

If multiple pumps operate in parallel to maintain continuous flow, then flow continuity is improved, but flow rate consistency during transitions deteriorates

Engineering Contradiction:

Improveflow continuityVSAvoidflow rate consistency

Core Design Contradiction:

Duration of action of stationary objectVSStability of the object's composition

Solution Approach 1:

The system merges the throttling control of multiple parallel pumps into a coordinated operation. When pumps transition on or off, the controller adjusts the throttle positions of remaining active pumps to compensate, ensuring that the combined flow rate remains consistent. This coordinated merging of control actions maintains both continuity and consistency during transitions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system ensures continuous useful action by maintaining stable total flow rate throughout pump transitions. Rather than allowing interruptions or variations during pump on/off sequences, the throttling control continuously adjusts to preserve consistent flow, making the transition process itself continuous and smooth rather than discrete and disruptive.

Inventive Principle:

Principle #20Continuity of useful action

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

This approach stabilizes the total flow rate by matching the flow increase and decrease rates, ensuring it remains within desired limits, thus maintaining consistent fluid flow during pump transitions.

Implementation Method 1

One or more pumps may be used to move the fracturing fluid in and out of the borehole

Methodology Applied

Scientific EffectFluid dynamics:

Implementation Method 2

fracturing requires the use of fracturing fluids to create fractures, keep the fractures open

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS12523216B2Method to smooth pump rate while fracturing

Publication Date: 2026.01.13 HALLIBURTON ENERGY SERVICES INC

AI summary

A method for controlling changes in pump flow rates. The method involves identifying a first plurality of pumps scheduled to go offline and calculating a corresponding total flow decrease rate. Additionally, a second plurality of pumps intended to go online is identified, and a total flow increase rate is calculated based on these pumps. A determination is then made as to whether the difference between the total flow decrease rate and the total flow increase rate exceeds a predetermined flow rate threshold. If the threshold is exceeded, pump throttling is implemented based on this determination to manage the change in flow rates.