Hydraulic Fracturing Pump Torque Sensor Failure Detection
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Solution Overview
Problem
Current hydraulic fracturing systems lack effective monitoring and prognostics for pump failures, leading to inefficiencies and unplanned downtime.
Innovation Solution
A system and method that includes a torque sensor to measure driveshaft torque and a controller to analyze this data, identifying pump failure modes by converting torque measurement data from a time domain to a frequency domain and comparing it to baseline data to detect cavitation and leakage events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hydraulic fracturing systems operate without advanced monitoring, then system complexity is reduced, but pump failure detection capability deteriorates leading to unplanned downtime
Solution Approach 1:
The patent replaces complex mechanical monitoring systems with an electrical sensor-based detection system. A torque sensor electrically coupled to the driveshaft measures torque fluctuations, and a controller processes these electrical signals to detect pump failures, substituting mechanical complexity with simpler electrical measurement and processing.
Solution Approach 2:
The torque sensor acts as an intermediary element between the driveshaft and the controller. It converts mechanical torque variations into electrical signals that the controller can process, enabling indirect detection of pump failures through torque measurement rather than direct mechanical inspection.
2Measurement precision
If no torque measurement system is installed, then installation cost and complexity are reduced, but ability to detect cavitation and leakage events deteriorates
Solution Approach 1:
The system implements feedback by continuously measuring torque on the driveshaft and comparing it against expected operational ranges. The controller receives real-time torque data from the sensor, processes it to identify anomalies indicating cavitation or leakage, and can trigger alerts or shutdowns based on the detected conditions.
Solution Approach 2:
The patent substitutes direct mechanical inspection methods with electrical torque measurement. Instead of mechanically monitoring pump conditions through complex diagnostic equipment, the system uses a torque sensor to electrically measure and analyze driveshaft torque, providing precise detection of abnormal operational conditions.
3Productivity
If pump failures are not monitored, then maintenance costs are reduced, but unplanned downtime and operational inefficiency increase
Solution Approach 1:
The system performs preliminary detection of pump failure conditions by monitoring torque fluctuations that precede actual failures. By identifying cavitation and leakage events early through torque analysis, the system enables proactive maintenance scheduling, allowing repairs to be planned and executed during scheduled downtime rather than causing unplanned operational interruptions.
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
Enables early detection of pump failures, reducing downtime and improving the reliability and efficiency of hydraulic fracturing operations by identifying abnormal torque patterns indicative of cavitation and leakage.
Implementation Method 1
A torque sensor is positioned and configured to measure torque acting on the driveshaft, with the torque sensor generating torque measurement data.
Implementation Method 2
The controller is also programmed to convert the torque measurement data from a time domain to a frequency domain, and identify a pump failure mode based on the torque measurement data in the frequency domain.
Data Source
AI summary
A hydraulic fracturing system with pump failure detection includes an engine, transmission, hydraulic fracturing pump and a driveshaft coupled between the transmission and the hydraulic fracturing pump to transfer torque from the engine to the hydraulic fracturing pump. A torque sensor is positioned and configured to measure torque acting on the driveshaft, with the torque sensor generating torque measurement data. A controller is programmed to analyze the torque measurement data and identify a pump failure mode based on the torque measurement data.