Hydraulic Fracturing Unit Profiles for Predictive Maintenance Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The complex and time-consuming process of monitoring and determining maintenance needs for hydraulic fracturing equipment at a wellsite, which can lead to inaccurate assessments and reduced equipment lifespan due to missed maintenance, resulting in potential breakdowns.

Innovation Solution

A wellsite hydraulic fracturing system with a supervisory controller that collects and analyzes data from various sensors and controllers to build hydraulic fracturing unit profiles, assessing equipment health and determining maintenance schedules, ensuring optimal operation and reducing the risk of equipment failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual monitoring and maintenance determination is performed for hydraulic fracturing equipment, then equipment operation can be controlled, but the process becomes complex and time-consuming with inaccurate assessments

Engineering Contradiction:

Improvemaintenance assessment accuracyVSAvoidtime for monitoring and maintenance determination

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system enables equipment to self-monitor its own operational parameters and self-determine maintenance needs through integrated sensors and controllers that automatically track hours of use, operational status, and maintenance cycles without requiring manual intervention

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual monitoring processes are replaced with an automated electronic system comprising controllers, sensors, and a supervisory controller that automatically collects, processes, and analyzes equipment data to determine maintenance schedules

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual inspection of hydraulic fracturing units is performed to determine maintenance schedules, then maintenance can be identified, but the process is time-consuming and prone to interpretation errors

Engineering Contradiction:

Improvemaintenance schedule accuracyVSAvoidcomplexity of monitoring system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system continuously collects operational data from sensors and controllers, provides real-time feedback on equipment status and maintenance needs to the supervisory controller, and automatically adjusts maintenance scheduling based on actual equipment performance rather than fixed intervals

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The supervisory controller serves multiple functions including data collection from various equipment sources, data processing and analysis, maintenance schedule determination, and equipment selection for upcoming stages, consolidating what would otherwise require multiple separate systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If equipment is operated without timely maintenance to maintain productivity, then operational continuity is improved, but equipment lifespan is reduced leading to breakdowns

Engineering Contradiction:

Improveoperational continuityVSAvoidequipment lifespan

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system determines maintenance needs in advance by continuously monitoring equipment usage and comparing against maintenance cycles, allowing maintenance to be scheduled proactively before equipment failure occurs, thus preventing breakdowns while maintaining operational continuity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The automated system replaces manual judgment about when maintenance is needed with objective data-driven determination based on actual equipment usage hours and operational status, eliminating delays in identifying maintenance needs

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11649820B2Systems and methods of utilization of a hydraulic fracturing unit profile to operate hydraulic fracturing units

Publication Date: 2023.05.16 BJ ENERGY SOLUTIONS LLC

AI summary

A methods and system to operate hydraulic fracturing units may include utilizing hydraulic fracturing unit profiles. The system may include hydraulic fracturing units may include various components. The components may include an engine and associated local controller and sensors, a transmission connected to the engine, transmission sensors, and a pump connected to the transmission and powered by the engine via the transmission and associated local controller and sensors. A supervisory controller may control the hydraulic fracturing units. The supervisory controller may be in communication with components of each hydraulic fracturing unit. The supervisory controller may include instructions to, for each hydraulic fracturing units, obtain hydraulic fracturing unit parameters, determine a hydraulic fracturing unit health assessment, and build a hydraulic unit profile including the health assessment and parameters. The supervisory controller may, based on the health assessment, determine the hydraulic fracturing unit's capability to be operated at a maximum power output.