High-Pressure Filter Switching for Continuous Pump Operation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional high-pressure filters in the resource recovery industry require manual operation, leading to non-productive time and potential equipment failure due to the need to de-energize high-pressure pumps during filter changes or bypass operations, which strains the pumps and affects fluid properties.

Innovation Solution

An automated high-pressure filter system with sensors and a controller that monitors pressure differentials and flow rates to remotely control valve actuation, enabling seamless switching between filters and bypass lines while maintaining fluid circulation, allowing for real-time adjustments and filter maintenance without stopping high-pressure pumps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual filter operation is used, then device complexity is reduced, but non-productive time increases and equipment reliability deteriorates

Engineering Contradiction:

Improveequipment reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The filter system performs self-monitoring and self-switching operations through automated pressure differential sensing and valve control. The system detects when filters need maintenance and automatically switches between filters without human intervention, allowing the system to serve itself and eliminate manual operation requirements.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system continuously monitors pressure differential across filters and uses this feedback to automatically trigger switching operations. Pressure sensors provide real-time data to the control system, which responds by actuating valves to switch between filters when predetermined thresholds are reached, creating a closed-loop control system that improves reliability through continuous monitoring and automatic response.

Inventive Principle:

Principle #23Feedback

2Productivity

If high-pressure pumps are de-energized during filter changes, then filter maintenance can be performed, but productivity decreases and pump strain increases

Engineering Contradiction:

Improvecontinuous operationVSAvoidfilter maintenance

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system maintains continuous fluid circulation and pump operation during filter maintenance by implementing automated switching between multiple filters. When one filter reaches its pressure differential threshold, the system automatically switches to a second filter, allowing the first filter to be maintained without interrupting the useful action of fluid filtration and circulation.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The filter system is divided into multiple independent filter units (first filter and second filter) that can operate independently. This segmentation allows one filter to be taken offline for maintenance while the other continues to perform filtration, enabling maintenance operations without stopping the overall system and maintaining continuous productivity.

Inventive Principle:

Principle #1Segmentation

3Loss of time

If manual switching between filters is performed, then device complexity is minimized, but loss of time increases and equipment reliability decreases

Engineering Contradiction:

Improvenon-productive timeVSAvoidautomation level

Core Design Contradiction:

Loss of timeVSExtent of automation

Solution Approach 1:

The system replaces manual mechanical switching operations with automated electronic control. Pressure sensors electronically detect when filters need switching, and electronic valve actuators automatically perform the switching function, eliminating the need for manual mechanical operations and significantly reducing non-productive time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs preliminary monitoring of pressure differentials continuously, so that switching operations are triggered automatically at the optimal moment before filter performance deteriorates. This preliminary detection and automatic triggering eliminates delays associated with manual inspection and decision-making, reducing non-productive time while implementing comprehensive automation.

Inventive Principle:

Principle #10Preliminary action

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

The system enhances filter reliability, reduces non-productive time, extends equipment life, and improves hydrocarbon recovery by enabling continuous fluid circulation and real-time adaptation to changing conditions.

Implementation Method 1

determining, by a processing device, a first pressure differential across a first high-pressure filter

Methodology Applied

Scientific EffectPressure differential measurement: Pressure Gradient

Data Source

PatentUS12576349B2Automated control of high-pressure filter systems

Publication Date: 2026.03.17 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

Examples described herein provide a method that includes determining, by a processing device, a first pressure differential across a first high-pressure filter of an automated high-pressure filter system. The method further includes selectively controlling, by the processing device and based at least in part on the first pressure differential, a switching unit of the automated high-pressure filter system to cause fluid to selectively flow through at least one of the first high-pressure filter and a bypass line of the automated high-pressure filter system.