Power Sequencing for Pumping Systems Using Segmented Drives

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Solution Overview

Problem

Existing pumping systems rely on expensive and power-hungry variable frequency drives, which are not efficiently utilized when not all pumps require adjustable pumping rates, leading to resource wastage and increased costs.

Innovation Solution

Implementing a combination of variable frequency drives and soft-starters in pumping systems, where variable frequency drives power-up only those pumps needing adjustable rates, while soft-starters maintain constant speed for others, with a control system managing power allocation to optimize resource use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If variable frequency drives are used for all pumps, then adjustable pumping rates are achieved, but cost and power consumption increase

Engineering Contradiction:

Improveadjustable pumping ratesVSAvoidpower consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The system segments the pump fleet into two groups: those requiring variable speed control (powered by variable frequency drives) and those requiring constant speed (powered by soft-starters). This segmentation allows the system to achieve adjustable pumping rates only where necessary, reducing overall power consumption and cost while maintaining adaptability for pumps that require it.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different power control technologies to different pumps based on their specific operational requirements. Variable frequency drives are applied locally to pumps needing variable pumping rates, while soft-starters are applied to pumps requiring constant speed. This local differentiation optimizes resource allocation and reduces unnecessary energy consumption.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If variable frequency drives are used for all pumps, then adjustable pumping rates are achieved, but system cost increases

Engineering Contradiction:

Improveadjustable pumping ratesVSAvoidsystem cost

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system segments the pump fleet into two groups: those requiring variable speed control (powered by variable frequency drives) and those requiring constant speed (powered by soft-starters). This segmentation allows the system to achieve adjustable pumping rates only where necessary, reducing overall system cost while maintaining adaptability for pumps that require it.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses cheaper soft-starters for pumps that do not require variable speed control, replacing the more expensive variable frequency drives. This approach reduces system cost by using the less expensive soft-starters for pumps where the full functionality of variable frequency drives is not needed.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If variable frequency drives are used for all pumps, then adjustable pumping rates are achieved, but device weight and size increase

Engineering Contradiction:

Improveadjustable pumping ratesVSAvoiddevice weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

The system segments the pump fleet into two groups: those requiring variable speed control (powered by variable frequency drives) and those requiring constant speed (powered by soft-starters). This segmentation allows the system to achieve adjustable pumping rates only where necessary, reducing overall device weight and size by avoiding the use of heavy variable frequency drives for pumps that don't require variable speed control.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS10914154B2Power sequencing for pumping systems

Publication Date: 2021.02.09 HALLIBURTON ENERGY SERVICES INC

AI summary

A pumping system pumps material or fluid, for example, downhole to perform a stimulation operation. A pumping system may comprise multiple pumps that must be powered-up in a sequence that does not overload a power source. A variable frequency drive may be coupled to a pump via a motor and may adjust the speed of the motor to control the rate of pumping of fluid from the pump. A soft-starter may be coupled to a pump via a motor to provide a constant pumping rate of fluid from the pump. A power-up sequence may be determined that provides power to the variable frequency pump and the soft-starter to power-up the corresponding motors such that the power source is not strained or overloaded. Mixing variable frequency drive driven pumps with pumps driven by a soft-starter may provide an efficient use of available power, conserve space, allow for control over a pumping rate of fluid and reduce costs.