Fracturing Pump Control via Priority-Based Output Adjustment
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Solution Overview
Problem
Industrial fracturing operations require manual human judgment to manage multiple fracturing pumps of different driving modes, leading to inefficiencies due to the need for manual control to meet total required outputs and reduce energy costs.
Innovation Solution
A fracturing control system that automatically manages a plurality of fracturing pump sets by prioritizing their activation based on energy costs, adjusting operating parameters to maintain optimal output, and turning on/off pumps to meet required outputs while minimizing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual human judgment is used to manage multiple fracturing pumps, then operational flexibility is maintained, but control efficiency decreases and energy costs increase
Solution Approach 1:
The control system automatically manages multiple fracturing pumps by self-evaluating total required output, self-selecting which pump sets to activate based on priorities, and self-adjusting operating parameters without human intervention, thereby resolving the contradiction between manual flexibility and automated efficiency
Solution Approach 2:
The patent replaces manual mechanical control operations with an automated electronic control system that uses sensors, processors, and communication modules to manage pump operations, eliminating the need for human judgment while improving control efficiency and reducing energy costs
2Productivity
If more fracturing pump sets are activated to meet total required output, then productivity increases, but energy consumption increases
Solution Approach 1:
The control system dynamically adjusts operating parameters of pump sets based on total required output, selecting optimal combinations of pump sets and their operating parameters to meet production targets while minimizing energy consumption through automated parameter optimization
Solution Approach 2:
The system dynamically evaluates and adjusts the operational state of multiple pump sets in real-time, activating or deactivating specific pump sets based on current production requirements and energy cost considerations, allowing flexible adaptation to changing conditions
3Productivity
If automated control system is implemented, then control efficiency and energy cost reduction are achieved, but system complexity increases
Solution Approach 1:
The control system is designed with multi-functional capabilities, integrating output evaluation, pump set selection, parameter adjustment, and energy optimization functions into a single automated platform, reducing the need for multiple separate systems and managing complexity through functional integration
Data Source
AI summary
A fracturing control method is applied to a fracturing system including a plurality of fracturing pump sets. The method includes: turning on a first fracturing pump set according to a total required output of the fracturing system and priorities of the plurality of fracturing pump sets; adjusting an operating parameter of the first fracturing pump set according to an actual output of the first fracturing pump set and an output threshold corresponding to the first fracturing pump set, so that the actual output of the first fracturing pump set is f1 times the output threshold; and if the operating output of the first fracturing pump set is less than the total required output, turning on a second fracturing pump set, a priority of the second fracturing pump set being lower than a priority of the first fracturing pump set.