Fracturing Pump Rate Control for Wear and Fuel Reduction
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Solution Overview
Problem
Hydraulic fracturing operations require multiple diesel engines and transmissions for each hydraulic pump, leading to inefficiencies, increased wear, and high maintenance costs due to suboptimal pump rate settings and gear selections.
Innovation Solution
An optimization algorithm is employed to determine optimal pump rate setpoints for a plurality of fracturing pumps, minimizing costs and maximizing efficiency by solving a mixed-integer nonlinear programming problem, considering pump constraints and cost functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple diesel engines and transmissions are used for each hydraulic pump, then the hydraulic fracturing operation can be performed, but the system complexity and maintenance costs increase
Solution Approach 1:
The patent combines multiple hydraulic pumps into a single integrated hydraulic fracturing system where pumps share common power sources (diesel engines and transmissions). This merging reduces the total number of independent power units required, simplifying the overall system architecture while maintaining the necessary hydraulic fracturing capability.
Solution Approach 2:
The diesel engines and transmissions are designed to serve multiple hydraulic pumps simultaneously, making these power units multi-functional. Each engine-transmission combination can power different pumps at different times or in combination with others, increasing system efficiency and reducing the total number of power units needed.
2Ease of operation
If suboptimal pump rate settings are used, then the operation is simpler to control, but wear and maintenance costs increase
Solution Approach 1:
The control system continuously monitors pump operating parameters and automatically adjusts pump rate settings based on real-time conditions. This feedback mechanism ensures pumps operate at optimal rates without requiring complex manual intervention, simultaneously improving reliability through optimized operation and maintaining ease of operation through automated control.
Solution Approach 2:
The system dynamically adjusts pump rate settings based on varying operational conditions such as formation characteristics, well depth, and real-time performance data. This dynamic optimization allows the system to adapt to changing conditions automatically, reducing wear while maintaining operational simplicity through automated adjustment.
3Ease of operation
If non-optimal gear selections are used, then the operation is easier to manage, but fuel consumption increases
Solution Approach 1:
The control system monitors fuel consumption and operational parameters to automatically select optimal gear settings for each engine-transmission-pump combination. This feedback-driven gear selection ensures fuel-efficient operation without requiring operators to manually optimize gear choices, maintaining ease of operation while reducing energy consumption.
Solution Approach 2:
The system dynamically changes gear selection parameters based on real-time operational conditions, pump rate requirements, and fuel efficiency considerations. By automatically adjusting gear ratios and selections, the system optimizes fuel consumption while keeping the operation simple through automated parameter management.
Data Source
AI summary
Aspects of the disclosed technology provide solutions for optimizing pumps in hydraulic fracturing and, in particular, for determining optimal pump rate setpoints for a plurality of fracturing pumps. A process of the disclosed technology can include steps for coupling a plurality of fracking pumps to a respective controller and coupling a manifold to each of the fracking pumps. The process can further include steps for coupling a control system to each of the respective controllers, wherein the control system is configured to perform operations for receiving a total pump rate for the manifold and determining a plurality of pump rate setpoints for each of the plurality of fracking pumps and transmitting the plurality of pump rate setpoints to each of the respective controllers. Systems and machine-readable media are also provided.