Controlled Stop for Electric Pump Using Suction Valve
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High horsepower, direct drive electric pumps used in well stimulation operations face challenges in rapid stoppage due to stored kinetic energy, which can cause damage to the motor, powertrain, or surrounding environment, and existing solutions like diesel engines may not be suitable for all well site environments due to operational characteristics.
Innovation Solution
A controlled stop system utilizing an information handling system to decouple kinetic energy from the rotor, employing a valve train with a cylinder and rod mechanism to maintain the suction valve open, preventing fluid discharge and allowing gradual motor shutdown, and diverting pressurized fluid to a reservoir during power down sequences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the electric motor or powertrain is shutdown quickly to stop the pump, then the pump stops rapidly, but the kinetic energy stored in the rotor causes damage to the electric motor, powertrain, or surrounding environment
Solution Approach 1:
The suction valve is opened in advance before the motor shutdown is initiated. This preliminary action allows the pump to stop rapidly while the opened suction valve prevents pressure buildup and kinetic energy damage during the shutdown process
Solution Approach 2:
The suction valve acts as an intermediary mechanism between the rapid shutdown requirement and the kinetic energy management. By opening the suction valve, it mediates the stoppage process to allow rapid shutdown while preventing the harmful effects of kinetic energy release
2Speed
If the suction valve is kept closed during motor shutdown, then the pump can be stopped rapidly, but overpressurization occurs in the downstream pressurized fluid system
Solution Approach 1:
The suction valve is opened in advance before the motor shutdown sequence begins. This preliminary opening of the suction valve creates a pressure relief path that prevents overpressurization in the downstream system while enabling rapid pump stoppage
Solution Approach 2:
The suction valve opening provides a preliminary counter-action to the pressure buildup that would otherwise occur during rapid shutdown. By opening the valve beforehand, the system preemptively counteracts the potential overpressurization harm
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
Enables safe and instantaneous stoppage of electric pumps without causing damage, suitable for various well site environments by managing kinetic energy and preventing overpressurization, while maintaining operational control over pump rate and emissions.
Implementation Method 1
A valve train may be utilized to maintain the suction valve open. For example, the valve train may include a cylinder with a rod disposed in the cylinder
Implementation Method 2
pressurized fluid be diverted to a reservoir during a power down sequence
Data Source
AI summary
Certain conditions require powering down an engine driving a pump. During the down sequence the pump may continue pumping servicing fluid which may not be desirable. Activating one or more control valves may throttle or prevent the servicing fluid from being pumped from the pump during the power down sequence. Activation of an input control valve may introduce pressurized fluid into a cylinder of the pump extending a rod to force or maintain a suction valve in an open position. While the suction valve is in the open position, the stroke of the plunger may not create enough pressure to pump the servicing fluid causing the servicing fluid to flow between a fluid header and a chamber of the pump. Activation of an output control valve may divert servicing fluid pumped from the pump to a reservoir instead of to the desired location.