Pump Control Lookup Table for Lag Time Reduction
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Solution Overview
Problem
Current pump control systems in subterranean operations face delays in achieving desired flow rates due to wear and tear, leading to inefficiencies in fluid composition during processes like fracking, where shorter stage times are becoming increasingly critical.
Innovation Solution
Implementing a system with a closed-loop control algorithm and memory storage to recall optimized pump output values, allowing for quicker adjustment to desired flow rates by bypassing some of the delay caused by the control system's iteration cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a closed-loop control algorithm is used to maintain accurate pump flow rates, then manufacturing precision is improved, but loss of time increases due to iteration delays
Solution Approach 1:
The system performs preliminary actions by pre-calculating and storing the relationship between pump output control values and resulting flow rates in a lookup table during a calibration phase. When operation begins, the control system can immediately retrieve pre-computed values from the lookup table without performing real-time iterative calculations, thus maintaining flow rate accuracy while eliminating computation delay.
Solution Approach 2:
The system creates a simplified copy of the complex control relationship by storing discrete control value-flow rate pairs in a lookup table. Instead of performing complex real-time control calculations, the system copies the essential control information into a readily accessible table structure, allowing rapid retrieval of appropriate control values without iterative computation.
2Reliability
If traditional control systems are used with long stage times, then pump lag time is acceptable, but productivity decreases
Solution Approach 1:
The lookup table is pre-computed during a calibration phase before actual operation, storing the optimal control values for various desired flow rates. This preliminary action eliminates the need for time-consuming iterative calculations during production, enabling the system to maintain reliable control accuracy while supporting much shorter stage times and higher productivity.
Solution Approach 2:
The system replaces the traditional iterative mechanical control loop with a direct lookup-based control mechanism. Instead of continuously adjusting and measuring in real-time loops, the system substitutes a direct retrieval operation from the pre-computed lookup table, dramatically reducing control response time and enabling faster stage transitions.
Data Source
AI summary
Methods and systems wherein a first setpoint is used with a controller to translate the setpoint into a desired flow rate from a pump and used to determining an optimized command signal associated with the first setpoint with a process control system, the process control system configured to incorporate at least a first setpoint and a measurement signal to produce the optimized command signal. The optimized command signal is then stored in a memory of the computer. When the first setpoint is again desired, the optimized command signal associated with the first setpoint is read from the memory and transmitted to the pump.