Pump-as-Dynamometer Engine Monitoring for Frac Units
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Solution Overview
Problem
There is currently no means to measure the performance of all engines on frac pumping units in real-time, which hinders the ability to optimize the performance of an entire frac spread and maintain powertrain life.
Innovation Solution
Utilizing a pump as a dynamometer to monitor engine performance by comparing the output of the engine with the output of the pump, and using an information handling system to adjust for volumetric efficiency changes and determine engine conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional engine monitoring methods are used, then engine performance can be monitored to some extent, but real-time monitoring of all engines on frac pumping units is not possible
Solution Approach 1:
The pump serves multiple functions: its primary function of pumping fluid is maintained, and it simultaneously functions as a dynamometer to measure engine performance. By instrumenting the pump with sensors to measure torque and rotational speed, the same component performs both pumping and measurement functions, enabling real-time monitoring without adding separate measurement systems to each engine-pump unit.
2Reliability
If no real-time monitoring system is implemented, then system complexity remains low, but engine performance optimization and powertrain life management are hindered
Solution Approach 1:
The pump system monitors its own performance characteristics by measuring torque and rotational speed at the pump itself. This self-measurement approach eliminates the need for external dynamometers or complex remote monitoring systems, reducing overall system complexity while enabling real-time performance tracking and powertrain life management.
Solution Approach 2:
The pump acts as an intermediary between the engine and the measurement system. Rather than directly measuring engine parameters, the system measures pump parameters (torque and speed) which serve as proxies for engine performance. This intermediary approach simplifies measurement while providing reliable data for optimization and life management.
3Object-generated harmful factors
If engine performance degradation is not detected early, then operational simplicity is maintained, but emissions increase and equipment health deteriorates
Solution Approach 1:
The system continuously measures pump torque and rotational speed, compares actual performance against expected performance thresholds, and provides feedback when degradation is detected. This real-time feedback loop enables early detection of performance issues, allowing operators to take corrective action before emissions increase and equipment health deteriorates significantly.
Data Source
AI summary
The disclosure provides for a wellbore servicing system that comprises an engine operable to provide power to one or more pumps. The one or more pumps are operable to direct a fluid into a wellbore, wherein the engine is coupled to the one or more pumps via a transmission. The system further comprises an engine control module (ECM) coupled to the engine. The system further comprises a controller coupled to the one or more pumps and operable to determine the volumetric efficiency of each of the one or more pumps. The system further comprises an information handling system, wherein the ECM and the controller are communicatively coupled to the information handling system, wherein the information handling system is operable to determine a divergence when a load is placed on the engine and a pumping plan for the system.