Hybrid Fracturing Fleet Control for Diesel-Electric Pump Switching
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Solution Overview
Problem
Existing hydraulic fracturing fleets struggle to integrate diesel and electric equipment effectively, lacking software capable of operating both types simultaneously, leading to inefficiencies in manpower, space utilization, and data logging complexity.
Innovation Solution
A datavan equipped with a multi-pump control station and controller that switches between diesel and electric components based on failure determinations, using software to manage parameters and inputs from sensors, enabling seamless integration and operation of both types of equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If diesel and electric equipment are integrated in the same hydraulic fracturing fleet, then productivity and efficiency are improved through optimized pump rate coordination and space utilization, but device complexity increases due to the need for software control systems that can manage both diesel and electric components simultaneously
Solution Approach 1:
The controller is designed with multi-functionality to manage both diesel-powered and electric-powered components through a unified control interface. The datavan software serves as a universal control system that can operate different power source types without requiring separate control systems, thereby improving productivity while managing complexity through consolidation.
Solution Approach 2:
The controller acts as an intermediary between the operator and both diesel and electric equipment. It translates operator commands into appropriate actions for each equipment type and coordinates their operation, simplifying the interface while managing the underlying complexity of integrating different power sources.
2Ease of operation
If a unified control system manages both diesel and electric components, then ease of operation is improved through single interface control, but device complexity increases due to the need for failure detection and switching logic
Solution Approach 1:
The controller incorporates self-service capabilities through automatic failure detection and switching. When a failure is detected in either diesel or electric components, the system automatically switches to the alternative power source without requiring manual intervention, thereby maintaining ease of operation while managing complexity through automation.
Solution Approach 2:
The system uses feedback mechanisms to monitor the status of both diesel and electric components. Sensors and control systems continuously report equipment status to the controller, which processes this information and automatically adjusts operation or switches power sources when failures are detected, maintaining simple operation despite the complex switching logic.
Data Source
AI summary
A hydraulic fracturing fleet with a controller associated with a datavan, the controller to switch between diesel-powered components supported by a diesel engine and electric-powered components supported by an electric pump, the switch to occur upon determination of a failure that is indicated by the diesel-powered components or the electric-powered components to the controller, wherein the failure indicates a failure of at least one of the diesel-powered components or at least one of the electric-powered components, and wherein the controller is configured to shut down the at least one of the diesel-powered components or the at least one of the electric-powered components indicated by the failure and ramp up one of another diesel-powered component or another electric-powered component in response to the shut down.