Fracturing Fleet Pumping Sequence Control With Automated Exception Handling
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Solution Overview
Problem
Manual intervention in fracturing fluid pumping sequences leads to costly delays and safety hazards due to unpredictable exceptions, especially for inexperienced service personnel, and existing automated systems lack effective automated exception handling.
Innovation Solution
An automated pumping sequence managed by a managing application that retrieves and executes a pumping sequence from a storage server, includes automated exception handling, and optimizes equipment selection based on real-time data and customer criteria, using scripting languages like Python or Java to control fracturing units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used to handle exceptions in fracturing fluid pumping sequences, then service personnel can address unpredictable issues, but costly delays and safety hazards occur due to inexperience and manual response time
Solution Approach 1:
The system performs preliminary action by pre-programming exception handling scripts that automatically execute when specific exceptions occur. The managing application contains predefined scripts for common exceptions (equipment failures, formation issues, fluid problems) that are ready to run immediately upon detection, eliminating the need for manual assessment and response time.
Solution Approach 2:
The system implements self-service through automated exception handling where the managing application independently detects, diagnoses, and corrects exceptions using pre-programmed scripts. The system monitors equipment data, automatically identifies exceptions, executes appropriate correction scripts, and returns to normal operation without requiring service personnel intervention for routine exceptions.
2Productivity
If automated pumping sequences are implemented without exception handling, then operational efficiency increases, but the system cannot handle unpredictable exceptions and requires manual intervention
Solution Approach 1:
The system implements feedback by continuously monitoring equipment data from sensors and comparing actual performance against expected parameters. When deviations indicate exceptions, the system automatically triggers appropriate handling scripts. The feedback loop includes real-time data collection, exception detection, script execution, and verification of correction effectiveness, enabling fully automated exception management.
Solution Approach 2:
The managing application implements universality by incorporating a library of multi-purpose exception handling scripts that can address various types of exceptions (equipment failures, formation issues, fluid problems). A single automated system handles diverse exception types through standardized script execution, eliminating the need for separate manual procedures for different exception scenarios.
3Reliability
If experienced service personnel manually manage pumping sequences, then exceptions can be handled with expertise, but labor costs increase and consistency varies
Solution Approach 1:
The system replaces the mechanical system of human expertise with an automated computational system. The managing application uses pre-programmed scripts that encode expert knowledge for handling various exceptions. Instead of relying on human judgment and experience, the system automatically executes predetermined correction procedures based on detected exception types, providing consistent expert-level handling without human variability.
Solution Approach 2:
The system implements parameter changes by dynamically adjusting pumping sequence parameters based on detected exceptions. When exceptions occur, the managing application modifies operational parameters (flow rates, pressures, timing) according to the executed exception handling scripts, automatically optimizing performance while managing the exception without requiring manual parameter adjustment.
Data Source
AI summary
A method of controlling a pumping sequence of a fracturing fleet at a wellsite. A managing application executing on a computer in the control van can retrieve the pumping sequence from a local or remote storage computer. The managing application can establish an electronic communication link to receive sensor data from a plurality of fracturing units. The managing application can control the plurality of fracturing units with a stage script with multiple sequential instructions for a pumping stage of a pumping sequence while receiving one or more periodic data sets from the plurality of fracturing units wherein the data sets are indicative of the current state of the pumping stage of the pumping sequence.