Decoupler Mechanism for Pump Load Balancing
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Solution Overview
Problem
In hydraulic fracturing operations, balancing the pumping load across multiple pumps is challenging, especially when one pump fails, as increasing the load on remaining pumps can be detrimental to their health, and existing methods lack efficient mechanisms for independent control and maintenance reduction.
Innovation Solution
The implementation of a system that allows for independent control of pumping units, including the ability to decouple underperforming pumps from the prime mover and redistribute the load among remaining units, using a decoupler mechanism and a computer-controlled system to manage the pumping operation, ensuring constant proppant delivery and reducing maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the load on remaining pumps is increased to compensate for pump failure, then the desired concentration and flowrate of proppant can be maintained, but the health and reliability of the remaining pumps deteriorates
Solution Approach 1:
The pumping system is divided into multiple independently controllable pumping units, each capable of operating autonomously. When one pump fails, the system segments the load distribution by individually controlling remaining pumps rather than forcing all pumps to share equal load, allowing optimized load allocation that maintains productivity while protecting pump health
Solution Approach 2:
The control system dynamically adjusts the operating parameters of remaining pumps based on real-time conditions and pump health status. Instead of static load distribution, the system continuously optimizes flowrate and pressure settings to maintain productivity while preventing overload conditions that would harm pump reliability
2Reliability
If multiple pumps are used to maintain desired proppant delivery, then the volume and redundancy are improved, but the complexity of balancing pumping properties among pumps increases
Solution Approach 1:
Each pumping unit is equipped with independent control capabilities that allow it to self-regulate its operation. The control system automatically monitors and adjusts pumping properties without requiring complex manual coordination, reducing operational complexity while maintaining redundancy through autonomous pump management
Solution Approach 2:
The system implements feedback control mechanisms that continuously monitor pumping properties and automatically adjust operations to maintain balance among multiple pumps. This closed-loop control simplifies the management of complex multi-pump systems by using real-time data to automatically optimize load distribution and maintain desired proppant delivery
Data Source
AI summary
A method for calibrating a unit controller with a managing process determining a position of a decoupler mechanism on the pumping unit. The managing process can calibrate the unit controller with a dual pump mode in response to determining the decoupler mechanism is in a coupled position. The managing process can calibrate the unit controller with a single pump mode in response to determining the decoupler mechanism is in a decoupled position with the pumping unit operating with the first fluid end coupled to the power end and the second fluid end decoupled from the power end. The system controller can pump a wellbore treatment fluid in accordance with the pumping unit in i) the dual pump mode or ii) the single pump mode.