Automated Manifold Valve Pairing for Fracturing Pumps
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Solution Overview
Problem
Current hydraulic fracturing operations face challenges with manual valve management, leading to potential miscommunication and safety risks due to the manual connection of fracturing pumps to manifold trailer valves, resulting in incorrect valve operation and increased risks of over-pressurization.
Innovation Solution
A computerized system that automatically pairs low pressure and high pressure valves with fracturing pumps by using pressure sensors and actuators to determine and record fluid connections, ensuring accurate valve operation and reducing manual error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual valve management is used in fracturing operations, then operational flexibility is maintained, but miscommunication and safety risks increase due to manual connection errors
Solution Approach 1:
The patent replaces manual mechanical valve operation with an automated computerized control system. Sensors detect pump operations and automatically actuate valves through actuators, eliminating manual mechanical operations. This substitution maintains operational flexibility while dramatically improving reliability by removing human error from the valve-pump pairing process.
Solution Approach 2:
The system implements feedback loops where sensors continuously monitor pump operations (pressure, flow rate) and relay this information to the computerized control system. The control system processes this feedback and automatically adjusts valve positions accordingly. This closed-loop feedback mechanism ensures accurate valve-pump pairing and prevents miscommunication errors.
2Adaptability or versatility
If manual connection of fracturing pumps to manifold trailer valves is performed, then adaptability to different job sites is maintained, but time consumption and potential for error increase
Solution Approach 1:
The system enables self-service automation where the computerized control system automatically identifies and pairs valves with pumps based on sensor data from the manifold trailer and pump operations. The system serves itself by autonomously determining connections without requiring manual intervention, thereby reducing time consumption while maintaining adaptability to different job site configurations.
Solution Approach 2:
The patent implements preliminary identification and pairing of valves to pumps before actual fracturing operations begin. The computerized system pre-establishes the valve-pump associations based on detected connections, so that when operations start, the system is already configured and ready to operate automatically. This preliminary action eliminates time-consuming manual pairing during critical operations.
3Ease of operation
If incorrect valves are opened or closed during fracturing operations, then operational simplicity is maintained, but over-pressurization and safety risks occur
Solution Approach 1:
The patent introduces a computerized control system as an intermediary between the operator and the valve control mechanism. Instead of directly controlling valves, the operator interacts with the automated system, which then mediates the actual valve actuation based on sensor data and pre-established valve-pump associations. This intermediary layer prevents incorrect valve operations while maintaining ease of operation through automated decision-making.
Solution Approach 2:
The system implements preliminary protective measures by pre-establishing correct valve-pump associations and automatically preventing incorrect valve operations before they can cause harm. The computerized control system proactively identifies potential errors and blocks them through automated control logic, thereby preventing over-pressurization and safety incidents before they occur rather than reacting after problems arise.
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 safety and operational efficiency by eliminating manual miscommunication, preventing over-pressurization, and reducing downtime and financial losses associated with incorrect valve operations.
Implementation Method 1
A pressure increase is detected on a selected pump of a plurality of pumps by a first pressure sensor
Implementation Method 2
a pressure decrease is detected on the selected pump, corresponding to the opening of a selected high pressure valve
Data Source
AI summary
A manifold trailer and pairing system are disclosed. The pairing system has a non-transitory computer readable medium storing processor executable code. The processor executable code causes a processor to receive identification data indicative of a first low pressure valve and a second low pressure valve connected to a low pressure manifold of a manifold trailer; receive identification data indicative of a first high pressure valve and a second high pressure valve connected to a high pressure manifold of the manifold trailer; and receive identification data indicative of a plurality of pumps. The processor determines a first association indicative of a first fluid connection between the first low pressure valve and a selected pump and a second association indicative of a second fluid connection between the selected pump and a selected high pressure valve. The processor populates the non-transitory computer readable medium with information indicative of the first and second associations.