Hydraulic Fracturing Supervisory Controller for Flow Rate and Pressure Control
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Solution Overview
Problem
The complexity of hydraulic fracturing operations with numerous units makes it difficult to efficiently and effectively control the output of hydraulic fracturing units, leading to delayed responses to issues like well screen outs and over-pressure events, which can result in equipment damage and operational inefficiencies.
Innovation Solution
Implementing a semi- or fully-autonomous supervisory controller system that receives operational parameters, determines unit capacity, and adjusts flow rates according to controlled schedules to maintain target flow rates or pressures, generating signals for failures and adjusting outputs to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual control of numerous hydraulic fracturing units is used, then operational flexibility is maintained, but response time to issues like well screen outs and over-pressure events is delayed
Solution Approach 1:
The supervisory controller automatically monitors operational parameters and adjusts flow rates of hydraulic fracturing units without human intervention. The system self-regulates by detecting issues like well screen outs and over-pressure events, then autonomously coordinating pump output reductions across multiple units, eliminating the need for manual operator response while maintaining system reliability.
Solution Approach 2:
The system continuously monitors operational parameters from sensors on hydraulic fracturing units and uses this feedback to automatically adjust flow rates. When parameters indicate problems such as over-pressure or screen outs, the supervisory controller receives real-time data and immediately coordinates appropriate responses, creating a closed-loop control system that improves response time while managing complexity through automation.
2Reliability
If output of hydraulic fracturing units is reduced to prevent equipment damage, then equipment safety is improved, but operational efficiency decreases
Solution Approach 1:
The supervisory controller is pre-programmed with protocols for various equipment safety scenarios. When potential issues are detected through sensor feedback, the system executes predetermined coordinated responses that gradually reduce flow rates across multiple units, preventing equipment damage while maintaining operational continuity. This preliminary preparation allows rapid response without complete operational shutdown.
Solution Approach 2:
The system dynamically adjusts flow rates based on real-time conditions rather than using fixed reduction protocols. The supervisory controller continuously monitors operational parameters and modulates pump outputs proportionally to the severity and type of issue detected, allowing equipment safety protection while minimizing impact on overall productivity through adaptive, rather than static, control.
3Reliability
If coordinated reduction of multiple hydraulic fracturing unit outputs is implemented, then equipment damage is prevented, but control complexity increases
Solution Approach 1:
The patent combines multiple individual unit controls under a single supervisory controller that manages coordinated output adjustments across numerous hydraulic fracturing units. By merging control functions into one centralized system, the complexity of coordinating multiple units is consolidated and automated, allowing equipment protection through coordinated reduction without proportionally increasing operational complexity.
Solution Approach 2:
The supervisory controller serves multiple functions simultaneously: it monitors operational parameters, detects equipment issues, coordinates flow rate reductions across multiple units, and maintains system-wide optimization. This multi-functionality consolidates what would otherwise require separate control systems for each unit, protecting equipment while managing coordination complexity through a universal control platform.
Data Source
AI summary
Systems and methods for operating hydraulic fracturing units to pump fracturing fluid into a wellhead may include receiving a target flow rate and/or a target pressure for fracturing fluid supplied to the wellhead. The systems and methods may increase a flow rate from the hydraulic fracturing units according to a controlled increasing flow rate schedule toward the target flow rate and/or target pressure. When it has been determined the target flow rate and/or target pressure has been achieved, the systems and methods also may include operating the hydraulic fracturing units to maintain the target flow rate and/or target pressure. When the target flow rate has not been achieved, the systems and methods also may include generating notification signals, and/or when the target pressure has not been achieved, the systems and methods further may include operating the hydraulic fracturing units to maintain a maximum flow rate.