Fracturing Pumping Sequence Control With Automated Exception Handling
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Solution Overview
Problem
Manual intervention in fracturing fluid pumping processes leads to costly delays and safety hazards due to unpredictable exceptions, such as equipment failures and environmental risks, which inexperienced personnel may struggle to handle effectively.
Innovation Solution
An automated pumping sequence system with integrated exception handling, utilizing a managing application that monitors equipment data, identifies deviations, and applies automated remedial actions to maintain the pumping process, optimizing equipment selection and handling common exceptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual intervention is used in fracturing fluid pumping processes, then personnel can handle equipment operations, but costly delays and safety hazards occur due to unpredictable exceptions and inexperienced personnel
Solution Approach 1:
The system enables self-service through automated exception handling that operates independently without human intervention. The automated script monitors equipment data, detects exceptions, and executes remedial actions autonomously, allowing the system to service itself during normal and exceptional operations.
Solution Approach 2:
The system implements continuous feedback loops where equipment data is monitored in real-time, compared against expected parameters, and used to trigger automated responses. This closed-loop control ensures the system adapts to changing conditions and maintains reliable operation.
2Adaptability or versatility
If manual intervention is used to handle exceptions, then personnel can respond to equipment failures, but unpredictable delays occur due to human response time and inexperience
Solution Approach 1:
The system performs preliminary action by pre-programming exception handling logic and remedial actions. When exceptions occur, the automated script executes predetermined responses immediately, eliminating the need for human analysis and decision-making time.
Solution Approach 2:
The system replaces the mechanical human response system with an automated computational system. The automated script processes exceptions through electronic data analysis and automated control signals, substituting human cognitive and physical response mechanisms with faster electronic systems.
3Productivity
If automated pumping sequence is implemented, then operational efficiency increases and safety risks reduce, but device complexity increases due to automated exception handling system
Solution Approach 1:
The automated exception handling system is designed to be universal, capable of monitoring multiple equipment parameters and handling various types of exceptions through a single integrated platform. This multi-functionality consolidates what would otherwise require multiple separate systems into one cohesive solution.
Solution Approach 2:
The system merges monitoring, analysis, decision-making, and execution functions into a single automated exception handling system. By combining these previously separate operations into one integrated automated process, the system achieves high productivity while managing complexity through consolidation rather than proliferation of separate components.
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.